Woodward 5437-1124 ProTech-GII Dedicated Backup Module
Woodward 5437-1124 is a dedicated backup module in the ProTech-GII series, compatible with the ProTech-GII overspeed protection system of models 8237-1596 an
d 8237-1600. Specifically designed for rotating equipment such as steam turbines, gas turbines, and water turbines in industrial applications, its core function is to real-time monitor the rotor speed and acceleration of equipment. When dangerous operating conditions such as overspeed or over-acceleration are detected, it quickly triggers shutdown protection actions to prevent equipment damage or safety accidents.
This module adopts a Triple Modular Redundancy (TMR) design and 2-out-of-3 (2oo3) voting logic, holding IEC 61508 SIL-3 functional safety certification, and is also compatible with industry standards such as API 670 and API 612. It can achieve highly reliable protection in harsh industrial environments, supporting online testing and hot module replacement to ensure the continuity and safety of equipment operation.
1. Core Technical Parameters
1.1 Environmental and Physical Parameters
| Parameter Category | Specific Specifications |
|---|---|
| Operating Temperature | -20 to +60 °C (-4 to +140 °F) |
| Storage Temperature | -20 to +65 °C (-4 to +158 °F) |
| Relative Humidity | Up to 95% RH (non-condensing) |
| Vibration Protection | 0.04 G²/Hz, 1.04 Grms, 10 to 500 Hz |
| Shock Protection | 30 G, 11 ms half-sine pulse |
| Protection Grade | Compatible with IP56 enclosure (panel-mounted type requires installation in IP56 grade cabinet) |
| Weight | Approximately 10 kg (total weight of panel-mounted system) |
| Mounting Method | Suitable for panel mounting (corresponding to the panel-mounted design of the main system) |
| Sulfur Corrosion Resistance | Compliant with IEC 721-3-3 1994 environmental class 3C2 for H₂S and SO₂ gas concentration requirements |
1.2 Power Supply Parameters
| Power Supply Type | Specification Details |
|---|---|
| Input Type | 1 channel High Voltage (HV) + 1 channel Low Voltage (LV) dual input |
| HV Input Range | 90–264 Vac (47–63 Hz) or 100–150 Vdc, 30 W per module |
| LV Input Range | 18–32 Vdc (nominal 24 Vdc), 30 W per module |
| HV Input Inrush Current | 10 A at 115 Vac, 20 A at 220 Vac |
| LV Input Maximum Current | 1.5 A at 18 Vdc, 1 A at 32 Vdc |
| Reverse Polarity Protection | Supported (DC input) |
| Internal Relay Power Output | 24 Vdc ±10%, current limited to 500 mA |
1.3 Input / Output Parameters
1.3.1 Speed Input
| Input Type | Specification Parameters |
|---|---|
| Input Channel | 1 channel per module, supporting passive MPU or active probes (proximity, eddy current type) |
| Passive Probe (MPU) | Frequency range 100 Hz–32 kHz, input amplitude 1–35 Vrms, input impedance 1.5 kΩ |
| Active Probe | Frequency range 0.5 Hz–25 kHz, probe power supply 24 V ±10% @ 1 W, input threshold Vlow<2 vhigh="">4 V |
| Speed Measurement Accuracy | ±0.04% of current speed within the ambient temperature range of -20 to +60 °C |
| Acceleration Detection | Accuracy ±1% of current speed, detectable range 0–25000 rpm/s |
| Signal Cable Length | Up to 457 m (16 AWG low capacitance cable) |
1.3.2 Relay Output
| Output Type | Specification Parameters |
|---|---|
| Voting Trip Relay | 2 channels (synchronous action), Form C double SPDT type, contact capacity 8 A @ 220 Vac / 8 A @ 24 Vdc |
| Independent Trip Relay | 2 redundant channels, SPST solid state relay (normally open), 24 Vdc (max 32 V), 1 A |
| Alarm Relay | 1 channel, SPST solid state relay (normally open), 24 Vdc (max 32 V), 1 A |
| Relay Isolation | Trip relay 1500 Vac, other relays 500 Vac (relative to chassis and other circuits) |
| Output Cable Length | Up to 305 m (16 AWG low capacitance cable) |
1.3.3 Other I/O
| Interface Type | Specification Parameters |
|---|---|
| Dedicated Discrete Input | 3 channels (start, reset, speed fault bypass), input threshold ≤8 Vdc (OFF), ≥16 Vdc (ON), input current 3 mA ±5% (at 24 V) |
| Analog Output | 1 channel 4–20 mA isolated output, accuracy ±0.1% (25 °C), ±0.5% (full temperature range), resolution 12-bit, response time<2 ms |
| Serial Communication | 1 channel RS-232/RS-485 optional, supporting Modbus protocol, RS-485 maximum transmission distance 457 m, RS-232 maximum 15 m |
1.4 Response Time
| System Type | Response Time Range (when frequency >1000 Hz) |
|---|---|
| Independent Trip Relay Model (Speed Redundancy Manager disabled) | Minimum 4 ms |
| Independent Trip Relay Model (Speed Redundancy Manager enabled) | Maximum 19 ms |
| Voting Trip Relay Model (Speed Redundancy Manager disabled) | Maximum 25 ms |
| Voting Trip Relay Model (Speed Redundancy Manager enabled) | Maximum 30 ms |
2. Core Functions and Features
2.1 Fault Tolerance and Redundancy Design
Triple Modular Structure: The system consists of three independent modules A, B, and C. As a backup module, 5437-1124 can seamlessly replace any faulty module. Modules share input data and configuration information through a safety-certified CAN bus, and a single module failure does not affect the overall system operation.
2oo3 Voting Logic: A trip command requires at least two modules to trigger simultaneously, avoiding misoperation or missed protection caused by a single point of failure and improving system reliability.
Online Hot Replacement: Supports module replacement during equipment operation without shutdown. After replacement, parameters can be quickly synchronized through the configuration copy function to ensure production continuity.
2.2 Overspeed and Over-Acceleration Protection
Overspeed Detection: The overspeed trip threshold (0–32000 rpm) can be set through the front panel or Programming Configuration Tool (PCT), supporting passive/active speed probe signal acquisition with open-circuit detection function (passive probe mode only). It can be configured to trigger trip or alarm when open-circuit occurs.
Over-Acceleration Protection: The over-acceleration trip threshold (0–25000 rpm/s) can be configured, with support for setting an enable speed threshold. Over-acceleration protection is automatically disabled when the speed is lower than this threshold to avoid mis-triggering during startup.
Speed Redundancy Management: Configurable median, maximum or minimum voting logic, supporting 1–3 speed sensor signal inputs. Alarms are triggered when there are differences between multiple sensor signals, and the system can automatically switch to backup signals or trigger trips when a sensor fails.
2.3 Testing and Diagnostic Functions
Multiple Test Modes: Supports temporary overspeed setting test, manual simulated speed test, automatic simulated speed test and automatic sequence test, which can be remotely started through the front panel or Modbus without affecting normal equipment operation.
Complete Log Recording: Each module can record the latest 50 trip events, 50 alarm events and 20 overspeed/over-acceleration events, including event timestamp, peak speed/acceleration, fault cause and other information. Logs are stored in non-volatile memory and will not be lost when power is off.
Real-Time Status Monitoring: The front panel LCD can display current speed, acceleration, module status, fault code and other information, supporting Chinese/English language switching. Module health status can be quickly identified through LED indicators (green for normal, red for fault, yellow for alarm).
2.4 Communication and Integration Capability
Supports Modbus RTU protocol, which can be integrated with factory DCS systems or HMI to achieve remote monitoring and control (such as remote reset, test start, etc.). Communication parameters (baud rate, parity, slave address) can be flexibly configured.
The analog output can customize the 4–20 mA corresponding speed range, adapting to various display instruments or control systems with high output accuracy and strong anti-interference ability.
Compatible with other Woodward controllers and third-party PLC systems, supporting seamless integration with turbine control systems to achieve integrated protection.
3. Application Scenarios
The ProTech-GII system adapted to this module is widely used in:
- Power Industry: Overspeed protection of power generation equipment such as steam turbines, gas turbines and water turbines;
- Petrochemical Industry: Pipeline compressors, refinery turbines, rotating equipment in Liquefied Natural Gas (LNG) receiving stations;
- Industrial Manufacturing: Key rotating machinery such as large motors, pumps and compressors;
- Aerospace and Military Industry: Special turbines and key subsystems of engines.
4. Safety and Compliance Certifications
- Functional Safety Certification: IEC 61508 SIL-3;
- Explosion-Proof Certification: ATEX Zone 2, Category 3, Group II G, Ex nA IIC T4 X;
- North American Certification: CSA Class I, Division 2, Groups A-D, T4;
- Industry Standards: API 670, API 612, API 611;
- Electromagnetic Compatibility: EN 61000-6-2 (Immunity), EN 61000-6-4 (Emission).
5. Installation and Maintenance Points
- Installation Requirements: Must be vertically installed in a well-ventilated location free from strong magnetic interference, away from direct sunlight, water sources and condensation environments. The mounting surface must meet vibration protection requirements;
- Wiring Specifications: Power wiring uses 1.5–6 mm² (16–10 AWG) cables, I/O wiring uses 0.3–4 mm² (22–12 AWG) cables. Shielded twisted pair cables must be grounded in accordance with specifications to avoid parallel laying with high-voltage cables;
- Regular Maintenance: It is recommended to check wiring tightness, relay contact status and heat dissipation every 6–12 months. Automatic sequence tests can be configured every 1–999 days to verify the effectiveness of system protection functions;
- Firmware Upgrade: Supports firmware upgrade through PCT tool during shutdown window to obtain the latest functions and security patches.
Woodward Recommended Products
8237-1594
ProTech-GII series, bulkhead-mounted type, supporting HV/LV dual power input, independent relay output, with voting input function
8237-1598
ProTech-GII series, panel-mounted type, HV/LV dual power supply, independent relay output, adapted to voting input scenarios
8237-1595
ProTech-GII series, bulkhead-mounted, dual HV power input, independent relay, supporting voting input
8237-1599
ProTech-GII series, panel-mounted, dual HV power supply, independent relay output, with voting input function
8237-1596
ProTech-GII series, bulkhead-mounted, HV/LV power supply, voting relay output, supporting voting input
8237-1600
ProTech-GII series, panel-mounted, HV/LV power supply, voting relay output, adapted to voting input scenarios
5437-1126
Dedicated backup module for ProTech-GII, compatible with models 8237-1594 and 8237-1598
5437-1127
Backup module for ProTech-GII, compatible with models 8237-1595 and 8237-1599
8237-1656
ProTech-GII series, bulkhead-mounted, dual HV power supply, voting relay output, simplified function version
8237-1660
ProTech-GII series, panel-mounted, dual HV power supply, voting relay output, simplified function configuration
3005319639