Woodward 505E Installation And Operational Manual
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Woodward 505E Installation And Operational Manual

Digital governor for extraction steam turbines
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Installation and Operation Manual
505E Digital Governor
for Extraction Steam Turbines
Volume 1
Manual 85018V1B

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  • Page 1 Installation and Operation Manual 505E Digital Governor for Extraction Steam Turbines Volume 1 Manual 85018V1B...
  • Page 2 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.

  • Page 3: Table Of Contents

    WARENESS 1. G ............1 HAPTER ENERAL NFORMATION Introduction......................1 General Description....................3 505E Inputs and Outputs..................4 Control Overview ....................8 Speed Control.......................10 Auxiliary Control ....................11 Load Sharing Input ....................12 Cascade Control....................12 Extraction/Admission Control ................13 Ratio/Limiter ......................13 HP and LP Valve Limiters ..................14 Starting Features ....................15...
  • Page 4 Speed, Casc, Aux, and Ext/Adm Dynamics Adjustments ......... 178 6. C ..............182 HAPTER OMMUNICATIONS Modbus Communication..................182 Port Adjustments ....................185 505E Control Modbus Addresses..............185 Specific Address Information................198 7. S ..............201 HAPTER ERVICE PTIONS Product Service Options..................201 Returning Equipment for Repair................
  • Page 5 Manual 85018V1 505E Digital Governor Illustrations and Tables Figure 1-1a. Overview of 505E Functionality (Notes) ..........5 Figure 1-1b. Overview of 505E Functionality ............6 Figure 1-1c. Overview of 505E Functionality ............7 Figure 1-2. Typical Extraction and/or Admission Steam Turbine......9 Figure 1-3. Typical Admission Steam Turbine .............10 Figure 1-4.
  • Page 6 Figure 5-1. Basic Program Architecture ............145 Figure 5-2a. Overview of Run Mode ..............147 Figure 5-2b. Overview of Run Mode ..............148 Figure 5-3. 505E Keypad and Display............... 149 Figure 5-4. SPEED Key Screens ..............151 Figure 5-5. Direct Setpoint Entry ............... 154 Figure 5-6.
  • Page 7 Manual 85018V1 505E Digital Governor Illustrations and Tables Table 6-7a. Analog Read Addresses ..............190 Table 6-7b. Analog Read Addresses ..............191 Table 6-7c. Analog Read Addresses ..............192 Table 7-8. Analog Write Addresses ..............192 Table 6-9a. Control Status .................193 Table 6-9b. Control Status .................194 Table 6-10.

  • Page 8: Electrostatic Discharge Awareness

    PCB from the control cabinet, place it in the antistatic protective bag. CAUTION 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...

  • Page 9: Chapter 1. General Information

    Chapter 1. General Information Introduction This manual (85018) describes the Woodward 505E Digital Governor for steam turbines with controlled extraction and/or admission pressure control. English versions are 9907-165, 9907-166, and 9907-167. The option charts below show the differences between the part numbers. Volume 1 of this manual provides installation instructions, describes the control, and explains the configuration (programming) and operating procedures.
  • Page 10 Classe I, applications Division 2 ou Zone 2. 505E Software Changes Covered in this Manual Revision 1. PROGRAM MODE: Made all start modes default to false to ensure a customer programmed the unit. Also added an error check to ensure Rated Speed (when programmed as a gen set) was less than max gov.

  • Page 11: General Description

    (24 characters each) display, and a set of 30 keys is located on the 505E’s front panel. This OCP is used to configure the 505E, make On- Line program adjustments, and operate the turbine/system. Easy to follow instructions are presented in English through the OCP’s two-line display and...

  • Page 12: 505E Inputs And Outputs

    Indication for Overspeed trip, and Isochronous Loadsharing between units. Using the 505E The 505E control has two normal operating modes, the Program Mode and the Run Mode. The Program Mode is used to select the options needed to configure the control to your specific turbine application. Once the control has been configured, the Program Mode is typically never again used, unless turbine options or operation changes.

  • Page 13: Figure 1-1A. Overview Of 505E Functionality (Notes)

    ASCII or RTU and the communications can be RS-232, RS-422, or RS-485. One computer (PC) port to be used for program configuration storage. An overview of the 505E functions is shown in Figure 1-1. Use this block diagram to match the control features to the site-specific application required.

  • Page 14: Figure 1-1B. Overview Of 505E Functionality

    505E Digital Governor Manual 85018V1 Figure 1-1b. Overview of 505E Functionality Woodward...

  • Page 15: Figure 1-1C. Overview Of 505E Functionality

    Manual 85018V1 505E Digital Governor Figure 1-1c. Overview of 505E Functionality Woodward...

  • Page 16: Control Overview

    The 505E control can be configured to operate single automatic extraction turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve. (The 505E can also operate the governor valve and the first extraction valve of multiple extraction turbines).

  • Page 17: Figure 1-2. Typical Extraction And/Or Admission Steam Turbine

    HP valve position and the LP valve position must be changed to maintain speed/load and admission. The movement of both valves is automatically calculated by the 505E’s ratioing logic based on the turbine performance parameters to minimize valve/process interaction.

  • Page 18: Speed Control

    Figure 1-3. Typical Admission Steam Turbine Extraction and Admission Turbines The 505E control can be configured to operate single automatic extraction and admission turbines by controlling the interaction of the governor (HP or high pressure) valve and the extraction (LP or low pressure) valve.

  • Page 19: Auxiliary Control

    Remote Speed Setpoint One of the 4–20 mA inputs can be configured to remotely adjust the speed setpoint. Typically, a process control external to the 505E interfaces with this input to regulate the turbine’s speed or load to control a related process.

  • Page 20: Load Sharing Input

    DSLC. The 505E’s internal summing junction adds this signal with the speed/load PID’s reference. In addition to loadsharing, the DSLC input to the 505E can be used to synchronize the unit to either the plant bus or to the utility.

  • Page 21: Extraction/Admission Control

    Remote Extraction/Admission Setpoint One of the 4–20 mA inputs can be configured to remotely adjust the Extr/Adm setpoint. The remote setpoint input directly affects the 505E’s Extr/Adm setpoint. The maximum rate at which the remote input signal can change the setpoint is programmable and can be changed in the Run mode.

  • Page 22: Hp And Lp Valve Limiters

    There are cases when this ratioing is not desired, these cases require decoupling of one or both valve outputs. There are three decoupling options available in the 505E: decouple HP (or inlet), decouple LP (or exhaust), or decouple both HP and LP. When controlling either...

  • Page 23: Starting Features

    The valve limiters also can be used to troubleshoot system dynamic problems. If it is believed that the 505E is the source of system instability, the valve limiters can be positioned to manually take over control of the valve positions.
  • Page 24 Either the Idle/Rated or the Auto Start Sequence functions must be programmed to perform critical speed avoidance. Within a critical speed range, the 505E moves the speed setpoint at the critical speed rate programmed and does not allow the speed setpoint to stop within the critical speed avoidance band.

  • Page 25: Figure 1-4. Overview With Auxiliary Configured As A Limiter

    Manual 85018V1 505E Digital Governor Figure 1-4. Overview with Auxiliary Configured as a Limiter Woodward...

  • Page 26: Figure 1-5. Overview With Auxiliary Configured As A Controller

    505E Digital Governor Manual 85018V1 Figure 1-5. Overview with Auxiliary Configured as a Controller Woodward...

  • Page 27: Figure 1-6. Overview With Decoupled Hp & Lp Ratio/Limiter, Auxiliary Configured As A Limiter

    Manual 85018V1 505E Digital Governor Figure 1-6. Overview with Decoupled HP & LP Ratio/Limiter, Auxiliary Configured as a Limiter Woodward...

  • Page 28: Figure 1-7. Overview With Decoupled Hp & Lp Ratio/Limiter, Auxiliary Configured As A Controller

    505E Digital Governor Manual 85018V1 Figure 1-7. Overview with Decoupled HP & LP Ratio/Limiter, Auxiliary Configured as a Controller Woodward...

  • Page 29: Keypad And Display

    Run Mode. SELECT: The Select key is used to select control of the 505E display’s top or bottom line variable. The @ sign is used to indicate which line (variable) can be adjusted by the adjust keys. Only when there is a changeable variable on both lines (dynamics, valve calibration modes) does the “select key”...
  • Page 30 505E Digital Governor Manual 85018V1 ADJ (adjust): In the Run Mode, the “ “ (adjust up) moves any adjustable parameter up (larger) and the “ “ (adjust down) moves any adjustable parameter down (smaller). PRGM (program): When the control is shutdown this key selects the Program Mode. While in the Run Mode this key selects a Program Monitor Mode.

  • Page 31: Watchdog Timer/Cpu Fault Control

    Manual 85018V1 505E Digital Governor ALARM (F1): Displays the reason for any alarm condition (last/newest alarm) when the key’s LED indicator is illuminated. Press the Scroll down arrow (diamond key) to display additional alarms. OVERSPEED TEST ENABLE (F2) : Permits the speed reference to be raised beyond the maximum controlling speed setpoint to test either the electrical or mechanical overspeed trip.

  • Page 32: Chapter 2. Installation Procedures

    505E into a new or existing application. Mechanical Data and Hardware Installation If so labeled on the enclosure, the 505E is UL/CUL listed for use in hazardous locations in UL file E156028. This Equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D (Class I, Zone 2, Group IIC) or non-hazardous locations only.
  • Page 33 IP56 panel or cabinet meets NEMA 4X or IP56 ratings respectively. A gasket is attached to the rear side of the package’s bezel to properly seal the 505E’s face-plate to a panel. All field wiring connects to the 505E through removable terminal blocks located on the 505E’s back side.

  • Page 34: Figure 2-1. 505E Control Layout (Standard Enclosure)

    505E Digital Governor Manual 85018V1 Figure 2-1. 505E Control Layout (Standard Enclosure) Woodward...

  • Page 35: Figure 2-2. 505E Bulkhead-Mounted Enclosure

    Manual 85018V1 505E Digital Governor Figure 2-2. 505E Bulkhead-Mounted Enclosure Woodward...

  • Page 36: Figure 2-3. Jumper Options

    505E Digital Governor Manual 85018V1 Figure 2-3. Jumper Options Figure 2-4. Jumper Locations Woodward...

  • Page 37: Figure 2-5. Cageclamp Terminal Blocks

    Volume 2 of this manual, for hardware Input/Output specifications. All inputs and outputs to the 505E are made through “CageClamp” terminal blocks on the bottom of the 505E package. For EMI reasons, it is recommend that all low-current wire (terminals 52 through 121) be separated from all high- current wire (terminals 1 through 51).

  • Page 38: Figure 2-6. Control Wiring Diagram

    505E Digital Governor Manual 85018V1 Figure 2-6. Control Wiring Diagram Woodward...

  • Page 39: Figure 2-7. Representative 505E I/O Schematic

    Manual 85018V1 505E Digital Governor Figure 2-7. Representative 505E I/O Schematic Woodward...
  • Page 40 The 505E is available with three different input power source selections. The part number of the 505E depends on the rating of the input power source it can accept. The ratings of the required input power source on each unit can be identified by the back panel sticker or control part number.

  • Page 41: Figure 2-8. Fuse Location

    505E Digital Governor Figure 2-8. Fuse Location A 24 V power supply is available within the 505E to power external transducers or devices. This supply has two breaker protected output channels. One power supply channel (VA1) is capable of providing 24 Vdc ±10%, @ 200 mA maximum output current, to power 505E current inputs and auxiliary devices.

  • Page 42: Figure 2-9. Shielded Wire Connections

    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 505E must sense an MPU voltage of 1 to 25 Vrms for proper operation.
  • Page 43 T = Gear Teeth M = Overspeed Test Limit Setting R = Gear Ratio If the signal is not within these limits, the 505E will respond with a speed sensor frequency error during the program checking procedure. Contact Inputs In general, contacts must change state for a minimum of 15 milliseconds for the control to sense and register a change in state.
  • Page 44 Analog input #1 is dedicated as the extraction/admission input signal. The remaining five analog inputs (2-6) are programmable. All 505E inputs have an input impedance of 200 Ω. Refer to Chapter 4 of this manual for a complete list of programmable analog input options.

  • Page 45: Relay Outputs

    20 mA output drivers of which to use to display a parameter externally. The analog output connections for the 505E are shown in Figure 2-7. All 505E analog outputs can drive into a maximum of 600 Ω. Refer to Chapter 4 of this manual for a complete list of programmable analog output options.

  • Page 46: Figure 2-10. Typical Rs-232 Communications

    RS-232 Wiring A RS-232 link is limited to a distance of 50 feet. The 505E control utilizes terminal blocks 114-117 and 106-109 for RS-232 connections. Figure 2-10 shows typical RS-232 communications connection. The transmit data (TXD), receive data (RXD), and signal ground (SIG GND) must be properly connected as shown.

  • Page 47: Figure 2-11. Typical Rs-422 Communications

    An advantage of RS-422 communications is that it uses a differential voltage and can accommodate much longer transmission distances. A RS-422 link can communicate up to a distance of 4000 feet. The 505E control utilizes terminal blocks 108- 113 and 116-121 for RS-422 connections. Figure 2-11 shows a typical RS-422 communications connection.

  • Page 48: Figure 2-13A. Preferred Multipoint Wiring

    Manual 85018V1 Communications Grounding and Shielding All three 505E communications ports are fully isolated from earth ground. The RS-422 and RS-485 specifications state that a ground wire is needed if there is no other ground path between units. The preferred method to do this for isolated ports is to include a separate wire in the ground cable that connects the circuit grounds together.

  • Page 49: Chapter 3. 505E Control Description

    The 505E may be programmed to operate single extraction, single admission or single extraction/admission turbines. For each of these turbine applications, the 505E’s Ratio/ Limiter may be configured to have the turbine’s HP and LP valves interact differently depending on the turbine’s function within a system.
  • Page 50 HP valve position and the LP valve position must be changed to maintain speed/load and extr/adm. The movement of both valves is automatically calculated by the 505E’s ratioing logic based on the programmed turbine performance parameters to minimize valve/process interaction.
  • Page 51 With this mode of operation: • Turbine inlet pressure can be controlled through either the 505E’s Auxiliary or Cascade PIDs. • Extr/Adm pressure/flow can only be controlled through the 505E’s Extr/Adm PID.
  • Page 52 In this operating mode the turbine’s HP and LP valve actions are fully de- coupled. The HP valve can be positioned by the 505E’s Speed, Cascade, or Auxiliary PIDs. The LP valve can only be positioned by the 505E’s Extr/Adm PID. The decoupled configuration allows control of a turbine’s inlet pressure without interaction from exhaust flow changes.

  • Page 53: Figure 3-2. Coupled Hp & Lp Mode

    Manual 85018V1 505E Digital Governor If configured for a decoupled ratio/limiter mode, the control starts by using the Coupled ratio/limiter, then switches to the Decoupled ratio/limiter when the Auxiliary or Cascade PIDs are enabled. The auxiliary PID, when configured as a limiter, has no influence on the ratio/limiter selection.

  • Page 54: Figure 3-3. Decoupled Inlet (Hp) Mode

    505E Digital Governor Manual 85018V1 COUPLED R/L LOGIC S @ MaxHP (Mx Lmtr) S @ MaxLP (Mx Lmtr) Ratio Logic Min/Max Lim Digital Ramp S @ MinLP (Min Lmtr) HP/ S S @ MinHP (Min Lmtr) HP/ P S’ Ext/Adm Priority Prgd...

  • Page 55: Figure 3-4. Decoupled Exhaust (Lp) Mode

    Manual 85018V1 505E Digital Governor COUPLED R/L Min/Max Lim LOGIC S @ MaxHP (Mx Lmtr) S @ MaxLP (Mx Lmtr) Ratio Logic Digital Ramp S’ S @ MinLP (Min Lmtr) HP/ S S @ MinHP (Min Lmtr) HP/ P Ext/Adm Priority Prgd...

  • Page 56: Speed Vs. Extr/Adm Priority

    If the 505E is programmed for ‘Speed priority only’ it will be in Speed priority at all times. If the 505E is programmed for ‘Speed priority with Extr/Adm priority on the LP Max limiter’, Speed Priority will be selected at all times except when the LP...

  • Page 57: Figure 3-6. Priority Flow Diagram

    Speed priority. This contact can either be open or closed when a 505E ‘RUN’ command is given. If the contact is open it must be closed to select Extr/Adm priority. If the contact is closed when a trip condition is cleared, it must be opened and re-closed to select Extr/Adm priority.

  • Page 58: Turbine Start

    (Start Perm Not Met). The alarm does not need to be cleared but the contact must be closed before the 505E will accept a ‘RUN’ command. After a ‘RUN’ command has been accepted, the start permissive contact will have no effect on operation.

  • Page 59: Turbine Start Modes

    1. Issue a RESET command (to reset all alarms and shutdowns) • At this point the 505E will ramp open the LP valve limiter to its maximum position. • If programmed as extraction only, the LP valve position will ramp to the maximum limit until extraction is enabled.

  • Page 60: Figure 3-7. Manual Start Mode Example

    1. Issue a RESET command (to reset all alarms and shutdowns) • At this point the 505E will ramp open the LP valve limiter to its maximum position. • If programmed as extraction only, the LP valve position will ramp to the maximum limit until extraction is enabled.

  • Page 61: Figure 3-8. Semiautomatic Start Mode Example

    1. Issue a RESET command (to reset all alarms and shutdowns) • At this point the 505E will ramp open the LP valve limiter to its maximum position. • If programmed as extraction only, the LP valve position will ramp to the maximum limit until extraction is enabled.

  • Page 62: Critical Speed Avoidance

    Manual 85018V1 3. Issue a RUN command • At this point the 505E will ramp open the HP valve to its maximum position at the ‘HP valve Limiter Rate’ setting. • The speed setpoint will ramp to the minimum controlling speed setting at the ‘Rate to Min’...

  • Page 63: Idle/Rated

    Idle/Rated The 505E is equipped with an Idle/Rated function which allows the 505E to automatically ramp turbine speed to the application’s Rated speed setting. When deselected, the turbine speed ramps down to the application’s Idle speed setting (as defaulted in the Service Mode).

  • Page 64: Figure 3-10. Idle / Rated Start

    Figure 3-10. Idle / Rated Start A Ramp-to-Idle speed or Ramp-to-Rated speed command may be selected from the 505E keypad, contact input, or Modbus. The last command given from any of these three sources dictates the function performed. If a 505E contact input is programmed to select between idle or rated speeds, idle speed is selected when the contact is open and rated speed is selected when it is closed.

  • Page 65: Automatic Start Sequence

    Automatic Start Sequence can be used with any one of the three start modes. The 505E can be configured to utilize an Automatic Start Sequence to start the turbine. This sequencing logic allows the 505E to perform a complete controlled system startup from zero speed to rated speed.
  • Page 66 15 rpm/sec. At 3400 rpm, the sequence would be completed. If the unit was tripped for 2 hours or less and restarted, the 505E would use the Hot Start parameters. If the unit was tripped for 22 hours or longer and restarted, the 505E would use the Cold Start parameters.

  • Page 67: No Idle Programmed

    Manual 85018V1 505E Digital Governor If a 505E contact input is programmed to function as a Halt/Continue command, the sequence is halted when the contact is open, and continued when the contact is closed. The Halt/Continue contact can be either open or closed when a Reset command is given.

  • Page 68: Speed Pid Operational Modes

    Generator Load control Speed Control When not programmed for generator applications, the 505E Speed PID operates in a Speed control mode at all times. When programmed for generator applications, the state of the generator and utility tie breakers determine the operational mode of the Speed PID.

  • Page 69: Figure 3-13. Speed Pid Control Modes

    Manual 85018V1 505E Digital Governor While in the Speed Control mode, the Speed PID will control a turbine at the same speed or frequency regardless of the load it is supplying (up to the unit’s load capability). With this configuration, no form of droop or second controlling parameter is used by the PID for stability or control.
  • Page 70 The Droop term, as used throughout this manual refers to a PID’s second controlling parameter. A second parameter representing unit load is fed back into the 505E’s Speed PID to allow it to control two parameters; speed when operating in an isolated mode, and unit load when paralleled to an infinite bus.

  • Page 71: Figure 3-14. Frequency And Unit Load Relationship

    505E must control another parameter. The 505E senses unit load through the turbine HP and LP valve positions or an analog input from a watt transducer sensing generator load. HP and LP valve positions are sensed by their respective 0-100% actuator drive currents.

  • Page 72: Figure 3-15. Speed Relationships

    It is recommended that a Woodward Real Power Sensor or equivalent watt transducer be used to sense generator load and feed it back to the 505E’s kW input for kW droop control. However, if kW droop is not used or programmed, the 505E uses a calculated load value based off of turbine’s HP and LP valve...
  • Page 73 The speed setpoint may be set to a specific level, by directly entering a setpoint value through the 505E keypad or Modbus communications. To enter a specific setpoint from the 505E keypad, press the SPEED key to view the speed control screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again.
  • Page 74 Manual 85018V1 When configured for generator applications a Minimum Load setpoint is used by the 505E to reduce the chance of reverse powering a unit upon closing the generator breaker. With the utility tie breaker closed, when a generator breaker closed indication is received, the Speed setpoint is stepped to the Minimum Load setting.
  • Page 75 Speed PID to be tuned for optimal response. When the 505E is configured for a generator application, the utility tie and generator breakers determine which set of dynamics is used by the Speed PID.
  • Page 76 Since RSS is a secondary speed setting function, the Speed PID must be in- control of the 505E’s LSS bus to allow the RSS to position the actuator. When configured as a generator application, the RSS will not take control unless both breakers are closed and the speed PID is in control.

  • Page 77: Synchronization

    The DSLC can be used as a synchronizer only or as a synchronizer and load control. When the DSLC is used as a synchronizer only, the 505E must be configured to accept the DSLC’s analog Speed Bias signal and have this input enabled.
  • Page 78 Synchronizing / Loadsharing A Woodward Digital Synchronizer & Load Control (DSLC) is used with a 505E to allow automatic generator synchronization to a bus and the sharing of load with other units (using DSLCs on the same bus). The Woodward DSLC is a microprocessor based generator load control designed for use on three-phase AC generators with Woodward speed controls and automatic voltage regulators.

  • Page 79: Figure 3-16. Loadsharing Logic

    The Utility Tie breaker contact input is used to enable and disable Load Sharing when the generator breaker is closed. If the Utility Tie contact is open, loadsharing is enabled, and the 505E’s internal Speed PID droop, Cascade, and Auxiliary modes are disabled (as defaulted in Service mode). If the Utility Tie contact is closed loadsharing is disabled and the 505E’s Speed PID droop,...

  • Page 80: Extraction And/Or Admission Turbine Control

    XXXX = open or closed Table 3-2. Load Sharing Logic When the 505E is programmed to use the DSLC for Synchronization and Load Sharing, the RMT key can be used to access and enable the Sync/Load Share function and monitor all function mode messages. See Chapter 5 for information on how to enable this function through the RMT key.

  • Page 81: Figure 3-17. Extr/Adm Control Diagram

    1% per second rate to its min or max limit, depending on the programmed settings. The 505E senses an input failure and issues an alarm if the 4–20 mA Extr/Adm input signal goes below 2 mA or above 22 mA.

  • Page 82: Extraction Control

    100% during system start-up the LP valve cannot be controlled below its 100% open position. All related Extraction enable permissives must be met before the 505E will allow the Extr/Adm PID to take control of a process.

  • Page 83: Admission Or Extr/Adm Control

    This contact can either be open or closed when a 505E trip condition is cleared. If the contact is open it must be closed to issue an enable command.
  • Page 84 This contact can either be open or closed when a 505E trip condition is cleared. If the contact is open it must be closed to issue an enable command.
  • Page 85 The Extr/Adm setpoint may be adjusted from the 505E keypad, external contacts, Modbus commands, or through a 4–20 mA analog input signal. A specific setting can also be directly entered from the 505E keypad or through Modbus commands. The Extr/Adm setpoint range must be defined in the program mode. Program settings ‘Min Extr/Adm Setpoint’...

  • Page 86: Remote Extr/Adm Setpoint

    Extr/Adm control will ramp the Extr/Adm process up or down to match the two signals. When the 505E is powered-up, the setpoint is reset to the ‘Setpt Initial Value’. With this configuration, if one of the permissives is lost or Extr/Adm control is disabled, the Extr/Adm setpoint will remain at its last setting until otherwise adjusted.
  • Page 87 Remote EXTR/ADM Setpt Messages Depending on configuration and system conditions, the Remote Extr/Adm Setpoint may be in one of the following states (505E front panel screen messages): • Disabled—The Remote Setpoint function is disabled and will have no effect on the Extr/Adm setpoint.

  • Page 88: Cascade Control

    The contact can be either open or closed when a 505E trip condition is cleared. If the contact is open it must be closed to enable the remote setpoint. If the contact is closed it must be opened and re-closed to enable the remote setpoint.

  • Page 89: Figure 3-18. Cascade Functional Diagram

    Manual 85018V1 505E Digital Governor If a contact input is programmed to function as a Cascade Enable contact, when the contact is open Cascade control is disabled, and when it is closed Cascade control is enabled. This contact can either be open or closed when a trip condition is cleared.
  • Page 90 Adjustments section in this manual. Cascade Setpoint The Cascade setpoint can be adjusted from the 505E keypad, external contacts, Modbus commands, or through a 4–20 mA analog input. A specific setting can also be directly entered from the 505E keypad or through Modbus commands.
  • Page 91 Manual 85018V1 505E Digital Governor A specific setpoint may also be directly entered from the 505E keypad or through Modbus communications. When this is performed, the setpoint will ramp at the ‘Casc Setpt Rate’ (as defaulted in Service mode). To “enter” a specific setpoint...

  • Page 92: Remote Cascade Setpoint

    Remote Cascade Setpoint The Cascade setpoint can be positioned through an analog signal. Optionally, one of the 505E’s analog inputs can be programmed to position the Cascade PID setpoint. This allows the Cascade setpoint to be positioned remotely by a process control or distributed plant control system.
  • Page 93 RCS is enabled. The contact can be either open or closed when a 505E trip condition is cleared. If the contact is open it must be closed to enable the RCS input. If the contact is closed, it must be opened and re-closed to enable the RCS input.

  • Page 94: Auxiliary Control

    505E Digital Governor Manual 85018V1 Auxiliary Control The Auxiliary PID controller can be used to limit or control generator power, plant import/ export power, turbine inlet pressure, turbine exhaust pressure, pump/compressor discharge pressure, or any other auxiliary parameters, directly related to turbine speed/load. The Auxiliary input is a 4 to 20 mA current signal.
  • Page 95 Manual 85018V1 505E Digital Governor The Aux setpoint initializes to the programmed ‘Setpt Initial Value’ setting on a power- up-reset. This setpoint may be adjusted at any time and will remain at a setting (running or shutdown), provided a power-up-reset did not occur.
  • Page 96 Auxiliary control will be disabled and inhibited when the 505E is in frequency control. If the Auxiliary milliamp input signal is out of range (below 2 mA or above 22 mA) an alarm will occur and Auxiliary control will be inhibited until the input signal is corrected and the alarm is cleared.
  • Page 97 Modbus communications. When this is performed, the setpoint will ramp at the ‘Aux Setpt Rate’ (as defaulted in Service mode). To enter a specific setpoint from the 505E keypad, press the AUX key to view the Auxiliary control screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again.
  • Page 98 Remote Setpoint input. If the contact is closed, it must be opened and re-closed to enable the Remote Setpoint input. When the Auxiliary PID is programmed to function as a limiter, the Remote Auxiliary Setpoint may be enabled at any time when the 505E is in the RUN mode. Woodward...

  • Page 99: Valve Limiters

    The valve limiters also can be used to trouble shoot system dynamic problems. If it is believed that the 505E is the source of system instability, the valve limiters can be positioned to manually take over control of the valve positions. Care should be taken when using the valve limiters in this fashion, to not allow the system to reach a dangerous operating point.
  • Page 100 ‘Valve Limiter Rate’ to the newly entered setpoint value. This ‘Entered’ rate is tunable through the Service mode. To adjust a limiter’s level from the 505E’s keypad, press the “LMTR” key to view the limiter screen. If the desired limiter (HP or LP) screen is not displayed press the Scroll Up/Down key to display it.

  • Page 101: Emergency Shutdown

    505E to indicate the cause of an emergency shutdown. By wiring trip conditions directly into the 505E, instead of a trip string, the 505E can pass a trip signal directly to its output relay (to trip the T&T valve), and also indicate the first trip condition sensed.

  • Page 102: Overspeed Test Function

    505E Digital Governor Manual 85018V1 With the control in the run mode and the turbine turning, when the 505E’s “STOP” key is pressed, the control will display a message prompting the operator to verify the command (Manual Shutdown ? / Push YES or NO). At this point if the “YES”...

  • Page 103: Local / Remote Function

    (F3, F4), or Modbus command. When Local mode is selected, the 505E is defaulted to be operable from its front panel only. This mode disables all contact inputs and Modbus commands, with...

  • Page 104: Function Keys

    See Chapter 6 for a complete listing of Modbus parameters. Function Keys Function keys F3 & F4 are located on the 505E’s front panel. They can be programmed independently to function as a control panel switch. These keys allow functions to be enabled and disabled from the 505E’s front panel, without requiring the use of an external switch.

  • Page 105: Relays

    505E Digital Governor Relays The 505E has eight relay outputs available. Two of these relays are dedicated; one for a system shutdown command from the 505E and one for alarm indication. The other six relays can be programmed for a variety of indications, and system functions.
  • Page 106 The 505E Control Status OK relay is normally energized, and will only de- energize if unit input power is lost, the 505E’s CPU fails, or the 505E is in the program mode. The Overspeed Test Enable relay will energize when an Overspeed Test is performed.
  • Page 107 Modbus command “Turn On Modbus Relay X” is issued, then de-energizes when the respective Modbus command “Turn Off Modbus Relay X” is issued. This feature allows a 505E relay to be driven directly from Modbus to control a system related function (i.e. synchronizing). In addition, the assigned relay can be momentarily energized using the Modbus command “Momentarily Energize Modbus Relay X”...

  • Page 108: Chapter 4. Configuration Procedures

    Program Architecture Figure 4-1. Basic Program Architecture The 505E is easy to program, due in large part to the menu-driven software. Basic program architecture is illustrated in Figure 4-1. When the control is powered up, and after the brief CPU self test has been completed, the control displays a ready status (Controlling Parameter/Push Run or Program).

  • Page 109: Figure 4-2. Initial 505E Program Mode Entry

    Figure 4-2. Initial 505E Program Mode Entry The touch keypad has several dual-function keys. Pushing any dual-function key in the Program Mode enters the appropriate numeric or yes/no value printed on the key.

  • Page 110: Programming The 505E

    Manual 85018V1 Programming the 505E Before the 505E can be used to operate any turbine, it must be configured with a valid program. A 505E Program Mode Worksheet is provided at the end of this manual. This chapter contains additional information related to completing this worksheet and programming the specific application.

  • Page 111: Figure 4-3A. Program Mode Blocks

    Manual 85018V1 505E Digital Governor All steps in the program must contain valid entries. The default values are listed along with any adjustment ranges, where applicable. If an invalid entry is made, the control displays an invalid entry message. If ENTER is pressed, the control displays the program step again so a valid entry can be made.

  • Page 112: Figure 4-3B. Program Mode Blocks

    505E Digital Governor Manual 85018V1 Figure 4-3b. Program Mode Blocks Woodward...

  • Page 113: Figure 4-3C. Program Mode Blocks

    Manual 85018V1 505E Digital Governor Figure 4-3c. Program Mode Blocks Woodward...

  • Page 114: Figure 4-3D. Program Mode Blocks

    505E Digital Governor Manual 85018V1 Figure 4-3d. Program Mode Blocks Woodward...

  • Page 115: Figure 4-3E. Program Mode Blocks

    Manual 85018V1 505E Digital Governor Figure 4-3e. Program Mode Blocks Woodward...

  • Page 116: Figure 4-3F. Program Mode Blocks

    505E Digital Governor Manual 85018V1 Figure 4-3f. Program Mode Blocks Woodward...
  • Page 117 The program blocks (Figure 4-3) contain information detailing each question and/or 505E program configuration option. Each question/option shows the default (dflt) value and the adjustable range of that parameter (shown in parentheses). In addition, any additional constraints on the configuration are shown in italics following the description.
  • Page 118 NO (Yes/No) Select YES followed by the ENTER key to configure an automatic start mode. When configured for an automatic start mode, the 505E controls the turbine speed from zero up to the minimum control speed. The Automatic Start Sequence would be: Operator opens the T&T valve, then push RUN.
  • Page 119 Enter YES followed by ENTER if this function is desired. If NO is selected followed by ENTER, then the program will step to ‘Reset Clears Trip Output’ question. If this function is programmed and RUN is selected, the 505E automatically accelerates the speed setpoint to a programmable low idle...
  • Page 120 Relay output function. When set to YES, a Reset command will energize the trip relay output even when a trip condition is still sensed by the 505E— typically due to one of the external trip inputs. Once reset, the unit will be ‘Ready to Start’...
  • Page 121 If all speed inputs fail, the 505E will issue a trip on loss of speed inputs. (Must be greater than or equal to 0.0204 x Overspeed Test Limit setting)
  • Page 122 OVERSPEED TRIP LEVEL (RPM) dflt= 1000 (0.0, 20000) Set the 505E’s overspeed trip level (in rpm) followed by the ENTER key. This is the governor overspeed trip setpoint only and is not to be used as ultimate overspeed protection.
  • Page 123 Manual 85018V1 505E Digital Governor USE CRITICAL SPEEDS ? dflt= NO (Yes/No) If NO, skip to ‘SPEED SETPOINT VALUES BLOCK’ heading. Set to YES followed by ENTER to use the critical speed avoidance logic. When set to YES, allows up to two critical speed avoidance bands to be programmed.
  • Page 124 505E Digital Governor Manual 85018V1 USE TIE BREAKER OPEN TRIP? dflt= NO (Yes/No) Select YES followed by the ENTER key if opening the utility tie breaker is to initiate a turbine trip. If YES, the unit will trip when the utility tie breaker opens after being closed unless a Controlled Stop is selected.
  • Page 125 Set to YES if LP valve output is to go to minimum (0%) on loss of extraction/ admission analog input signal. NOTE If the Response to all ‘Lost E/A Input’ questions is “NO”, the 505E will disable extraction/admission control and switch to manual setpoint at the last demand value.
  • Page 126 The 505E uses the values programmed to calculate the turbine’s internal pressure ratios and limits. In order to get these values from your steam map, you...
  • Page 127 LP=0 (extraction valve closed) and LP=100 (extraction valve fully open). Note that the LP=0 line is parallel to the LP=100 line (condition 2). The 505E can be configured for three different types of steam turbines, extraction only, admission only, or extraction/admission units. Following are examples for each of these configurations.

  • Page 128: Figure 4-4. Typical Extraction Steam Map

    505E Digital Governor Manual 85018V1 Point B is where the LP=0 and P=100 lines intersect (MIN POWER @ MAX EXTRACTION = about 3623 kW; HP FLOW @ MAX EXTRACTION = about 86 000 lb/h; 39 010 kg/h). Point C is where the LP=0 and P=0 lines intersect (MIN POWER @ MIN EXTRACTION = about -3000 kW;...
  • Page 129 Manual 85018V1 505E Digital Governor If points A & B already exist, the only conversion necessary is the extension of the LP=100 line and the P=100 line until they cross or intersect (this is Point C for programming). If only point A exists, your map will have to be modified to include points B & C.

  • Page 130: Figure 4-5. Typical Admission Steam Map

    505E Digital Governor Manual 85018V1 Figure 4-5. Typical Admission Steam Map Extraction & Admission Steam Map Before a turbine’s extraction/admission steam map can be programmed into the control, it must have the intersection points A, B, & C (refer to Figure 4-6).

  • Page 131: Figure 4-6. Typical Extraction & Admission Steam Map

    Manual 85018V1 505E Digital Governor 1. Extend the maximum extraction line. Refer to Figure 4-6. 2. Extend the zero extraction & admission line. 3. Find your turbine’s minimum back-end steam flow (this will be point C’s HP flow). 4. Mark the intersection of the zero extraction & admission flow line and the turbine’s minimum back-end steam flow.
  • Page 132 505E Digital Governor Manual 85018V1 The ten values needed can be taken from the converted steam map. An example has been provided below, using the steam map in Figure 4-6. The MAX POWER value is the load where the S=100 line crosses the s-axis (about 10 496 kW in our example).
  • Page 133 Manual 85018V1 505E Digital Governor EXTR AND ADMISSION ? dflt= YES (Yes/No) Set to YES if the turbine being controlled extracts and admits steam through the LP valve. If YES, skip to ‘Extr/Adm Steam Map Data’ Entry. Extraction Steam Map Data...
  • Page 134 505E Digital Governor Manual 85018V1 MIN POWER @ MIN ADM dflt= 10 (0, 20000) Minimum turbine power at min admission. Power at Point B. (Power must be less than Point C) MIN HP FLOW @ MIN ADM dflt= 50 (0, 20000) HP valve steam flow at min admission.
  • Page 135 ACTUATOR 1 (HP) IS 4–20 mA ? dflt= NO (Yes/No) Select actuator #1 output current range. Select YES for 4–20 mA or NO for 20–160 mA followed by the ENTER key. Most Woodward actuators are 20– 160 mA. INVERT DRIVER OUTPUTS ? dflt= NO (Yes/No) Set to YES to invert actuator driver outputs followed by the ENTER key.
  • Page 136 Select YES followed by ENTER to issue a trip whenever an actuator fault is detected. If YES, the 505E will issue a shutdown if Actuator 1 has a fault. If NO, an actuator fault alarm will be issued when a fault is detected. An...
  • Page 137 Manual 85018V1 505E Digital Governor ANALOG INPUT # 1 FUNCTION (extr/adm input) INPUT 1–4 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog input followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question.
  • Page 138 505E Digital Governor Manual 85018V1 CONTACT INPUT OPTIONS (Not Used) Casc Setpt Raise Generator Breaker Casc Setpt Lower Utility Tie Breaker Casc Control Enable Overspeed Test Remote Casc Setpt Enable External Run Aux Setpt Raise Start Permissive Aux Setpt Lower...
  • Page 139 Manual 85018V1 505E Digital Governor BLINK F4 LED WHEN NOT ACTIVE ? dflt= NO (Yes/No) Select YES followed by ENTER to blink the function key’s LED when the function is not active but is enabled. The LED will be ON whenever the function is active or in control.
  • Page 140 505E Digital Governor Manual 85018V1 AUX DROOP (%) dflt= 0.0 (0.0, 100) Enter the droop percentage followed by the ENTER key. If required, typically set between 4-6% and not more than 10%. AUX PID PROPORTIONAL GAIN (%) dflt= 1.0 (0.0, 100) Enter the aux PID proportional gain value followed by ENTER.
  • Page 141 Manual 85018V1 505E Digital Governor MIN CASCADE SETPOINT (UNITS) dflt= 0.0 (-20000, 20000) Set the minimum cascade setpoint followed by ENTER. This value is the minimum setpoint value that the cascade setpoint can be decreased/lowered to (lower limit of cascade setpoint).
  • Page 142 505E Digital Governor Manual 85018V1 RMT CASCADE MAX RATE (UNITS/SEC) dflt= 5.0 (0.01, 1000) Enter the maximum rate at which the remote input will move the cascade setpoint followed by the ENTER key. CASCADE UNITS OF MEASURE: (must choose from list)
  • Page 143 Shutdown Condition Extr/Adm PID in Control Trip Relay (add’l trip relay output) Remote Extr/Adm Setpt Enabled Alarm Condition Remote Extr/Adm Setpt Active 505E Control Status OK Cascade Control Enabled Overspeed Trip Cascade Control Active Overspeed Test Enabled Remote Casc Setpt Enabled...
  • Page 144 NO (Yes/No) Set to YES followed by ENTER to use the Modbus communications feature of the 505E. There are two identical Modbus ports available. Either or both can be configured for use. Select NO followed by ENTER if Modbus communications will not be used.

  • Page 145: Exiting The Program Mode

    “CLEAR’ key is pressed twice. This initiates the 505E to save the configuration and to begin a Configuration Check procedure. If there are no errors in the programming, the 505E front-panel will return to the ready state and display the ‘Controlling Parameter/Press Run or Program’ screen. However, if there is an error in the program, the ‘Config ERROR–Press PRGM’...
  • Page 146 Program mode under the Start Block. Speed > 15000 Hz—The maximum speed input is 15000 hertz. This is a limitation of the 505E’s hardware / speed sensing circuitry. The frequency input of the speed sensor must be less than this value. The gear the speed sensor is mounted on may need to be changed to one with less teeth, this will decrease the frequency seen by the speed probes.
  • Page 147 Manual 85018V1 505E Digital Governor Steam Map Prgm Error Steam Map Prgm Error—The map coordinates have been entered incorrectly. The calculations for power and flow in the control are wrong. Entries for points A, B, and C must be so the following equation is not true.

  • Page 148: Valve / Actuator Calibration And Test

    Valve Calibration procedure should be followed to insure that the 505E is calibrated to both valves. The 505E uses its actuator output currents to sense HP and LP valve positions. These valve positions are used by the 505E to calculate internal turbine ratios, and operating limits.
  • Page 149 505E to valve resolution. Figure 4-8 graphically shows the steps available to stroke the actuators or valves. The stroking option is only available when the 505E control is in a shutdown state. The emergency shutdown input has to be closed or jumpered, as this input being open will shut off the current outputs of the 505E.
  • Page 150 When calibration is complete, 0 to 100% valve position as displayed by the 505E must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the “CLEAR” key twice to save changes and exit Calibration mode.
  • Page 151 When calibration is complete, 0 to 100% valve position as displayed by the 505E must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the “CLEAR” key twice to save changes and exit Calibration mode.

  • Page 152: Figure 4-8. Stroke Actuator/Valve

    505E Digital Governor Manual 85018V1 Figure 4-8. Stroke Actuator/Valve Woodward...

  • Page 153: Chapter 5. 505E Operation

    Run Mode and the Program Mode. The Program Mode is used to configure the 505E for the specific application and set all operating parameters (see Chapter 4). The Run Mode is simply the normal turbine operation mode and is used to view operating parameters and run the turbine.
  • Page 154 505E Digital Governor Manual 85018V1 IDLE/RATED MESSAGES CONTROL PARAMETER TRIP MESSAGES MESSAGE 1 MESSAGE 7 MESSAGE 8 Stopped Controlling Parameter External Trip Input Mvg to Idle Control at Two Limits Enter Shutdown Button At Idle Spd Remote Auxiliary Overspeed In Crit Band...

  • Page 155: Figure 5-2A. Overview Of Run Mode

    Manual 85018V1 505E Digital Governor Figure 5-2a. Overview of Run Mode Woodward...

  • Page 156: Keypad And Display

    505E, make On-Line program adjustments, and operate the turbine/system. No additional panels are required to operate the turbine, every turbine control function can be from the 505E’s front panel. However, the turbine can also be operated remotely. Every front panel control operation can be performed remotely through contacts or Modbus communications.

  • Page 157: Run Mode Front Panel Keys

    Figure 5-3. 505E Keypad and Display Run Mode Front Panel Keys For a detailed description of each 505E key functionality see Chapter 1. Of the thirty front panel keys, not all are active at all times in the Run mode.

  • Page 158: Starting Procedures

    RUN command was issued. 3. After the selected start-up mode has been performed, the turbine will operate at the minimum or idle speed setting. The 505E’s speed setpoint will move to minimum governor speed unless an idle speed is programmed. The Idle/Rated or Auto Start Sequence functions must be programmed for the turbine to control at idle speed.

  • Page 159: Figure 5-4. Speed Key Screens

    Idle/rated Start For details on the idle/rated startup, refer to chapter 3. When a RUN command is issued, the 505E automatically displays the SPEED screen and shows the Idle/Rated status. The speed setpoint is instantly set to the actual turbine’s speed.
  • Page 160 Auto Start Sequence When a RUN command is issued, the 505E automatically displays the SPEED screen (unless used with the Semiautomatic start mode) and shows the Status of the Auto Start Sequence (screen 2). The Speed setpoint is instantly set to the turbine’s actual speed and the sequence will continue from this point.
  • Page 161 Manual 85018V1 505E Digital Governor The Sequence can be restarted again by pressing the front panel YES key from the Sequence Status screen (screen 2), closing the Halt/Continue contact, or selecting Continue from a Modbus communications link. Table 5-3 lists the Auto Start status messages that may appear on the display and the meanings of each.

  • Page 162: Overspeed Test Function

    Speed Sensor #2 Input, and Speed Control PID Output analog values are also available. Overspeed Test Function The 505E’s Overspeed Test function allows an operator to increase turbine speed above its rated operating range to periodically test turbine electrical and/or mechanical overspeed protection logic and circuitry. This includes the 505E’s internal overspeed trip logic and any external overspeed trip device’s settings...

  • Page 163: Figure 5-6. Overspeed Test Enable Key Screens

    Alternatively the turbine’s overspeed logic and circuitry can be tested remotely, by programming an Overspeed Test contact input. The Overspeed Test contact functions as the OSPD key on the 505E’s service panel. When the conditions outlined in the above procedure are met, closing this contact allows the Speed setpoint to be increased up to the “Overspeed Test limit”...

  • Page 164: F3 And F4 Keys

    505E Digital Governor Manual 85018V1 The Overspeed Test function cannot be performed over the communications links, however, the Overspeed Test Permissive, Overspeed Test In Progress, Overspeed Alarm, and Overspeed Trip indications are available through the Modbus links. F3 and F4 Keys The F-key (F3 &...

  • Page 165: Figure 5-7. Lmtr Key Screens

    Manual 85018V1 505E Digital Governor The following valve limiter indications are available through the Modbus links: HP Valve Limiter at Min, HP Valve Limiter at Max, and HP Valve Limiter In Control of actuator output, LP Valve Limiter at Min, LP Valve Limiter at Max, and LP Valve Limiter In Control of actuator output.

  • Page 166: Actuator (Actr) Key Screens

    505E Digital Governor Manual 85018V1 Actuator (ACTR) Key Screens Figure 5-8 shows the possible screens that may appear if the ACTR key is pressed. The only parameter that can be adjusted from these screens is the dither setting. To adjust the dither setting (if required), the @ symbol must be on the display line containing the asterisk/dither value to tune.

  • Page 167: Control (Cont) Key Screens

    Control (CONT) Key Screens Figure 5-9 shows the screens that appear when the CONT key is pressed. The CONT key allows operators to monitor what 505E parameters are controlling governor valve positions (screen 1). From screen 2 the steam map limiter priority can be seen and changed (if programmed).
  • Page 168 LP valve cannot be opened further (at max limit) LP Min Limit LP valve cannot be closed further (at min limit) Manual Start 505E is running and in the Manual start mode Auto Start 505E is running and in the Automatic start mode Semi Auto Start...

  • Page 169: Dynamics (Dyn) Key Screens

    To adjust the gain settings, the @ symbol must be on the respective display line of the value to be adjusted. The @ symbol is moved by pressing the SELECT key. The controller dynamics are adjustable from the 505E’s Service panel only, they cannot be adjusted remotely. Woodward...

  • Page 170: Stop Key Screens

    505E Digital Governor Manual 85018V1 Figure 5-10. DYN Key Screens Stop Key Screens Figure 5-11 shows the possible screens that may appear if the STOP key is pressed. The STOP key is used to perform a controlled/manual turbine shutdown or stop. To perform a Manual Shutdown, select YES from the Status screen or close the Controlled Shutdown contact input (if programmed) or select Controlled Shutdown from a Modbus communications link.

  • Page 171: Auxiliary (Aux) Key Screens

    Manual 85018V1 505E Digital Governor Figure 5-11. STOP Key Screens Auxiliary (AUX) Key Screens For this key to be active, the Auxiliary function must be programmed. Figure 5-12 shows the possible screens that may appear if the AUX key is pressed. Only the screens related to the Auxiliary control’s programmed functionality will be...
  • Page 172 505E Digital Governor Manual 85018V1 Auxiliary as a Controller (using Enable/Disable) When auxiliary control is used as a controller, as opposed to a limiter, the enable/disable function is used to select Auxiliary control. Auxiliary control can be enabled by pressing the front panel YES key from the Status screen (screen 2) or by closing the Aux Control Enable/Disable contact (if programmed) or by selecting Aux Enable from either Modbus communications link.
  • Page 173 Manual 85018V1 505E Digital Governor Auxiliary control is inhibited if a controlled shutdown is selected, the Auxiliary input fails, or the unit shuts down. See Table 5-7. Auxiliary control can be ‘enabled’ but not ‘active’ if the generator and/or utility tie breaker disable features are programmed.

  • Page 174: Remote / Speed Bias (Rmt) Key Screens

    505E Digital Governor Manual 85018V1 The following remote auxiliary control indications are available through the Modbus links: Remote Aux is Enabled, Remote Aux is Active, Remote Aux is In Control, Remote Aux is Inhibited, and Remote Aux Input Failed Alarm. In addition to these indications, the Remote Aux Input Setpoint is also available.
  • Page 175 Manual 85018V1 505E Digital Governor Remote Speed Setpoint The Speed PID setpoint can be remotely set by an analog input, if programmed. This Remote Speed Setpoint input can be enabled by pressing the front panel YES key from the Remote Speed Status screen (screen 6), closing the Remote...
  • Page 176 The bottom line of the display on screens 1, 2, & 3 show the calculated Load Setpoint. This value and units change depending on the droop mode the 505E is presently using. If the droop is based on the KW input, the units are in ‘KW’ or ‘MW’.

  • Page 177: Cascade (Cas) Key Screens

    Manual 85018V1 505E Digital Governor The Load Setpoint can be changed when the unit is On-Line from screens 1, 2, or 3 by selecting the ADJUST UP or DOWN. In addition, the Load Setpt can be adjusted by closing a Speed Setpoint Raise/Lower contact inputs or selecting Speed Setpoint Raise or Lower commands from either Modbus communications link.

  • Page 178: Figure 5-15. Cas Key Screens

    505E Digital Governor Manual 85018V1 Cascade control is disabled by pressing the front panel NO key from the Cascade Status screen (screen 2), opening the Cascade Control Enable/Disable contact (if programmed), or selecting Cascade Disable from either Modbus communications link. Cascade control is also disabled if Auxiliary control is enabled or Remote Speed Setpoint input is enabled.
  • Page 179 Manual 85018V1 505E Digital Governor The Cascade Setpt Raise/Lower contact inputs have a dual function. If either contact is closed and the Cascade control is active, the cascade setpoint will be adjusted. If either contact is closed and the Cascade control is not active, the Speed setpoint will be adjusted.

  • Page 180: Extraction/ Admission (Ext/Adm) Key Screens

    505E Digital Governor Manual 85018V1 The remote cascade control indications shown in Table 5-11 are available through the Modbus links: Remote Cascade is Enabled, Remote Cascade is Active, Remote Cascade is In Control, Remote Cascade is Inhibited, and Remote Cascade Input Failed Alarm. In addition to these indications, the Remote Cascade Input Setpoint is also available.
  • Page 181 All related Extraction permissives must be met before the 505E will allow the LP valve limiter to be lowered, and Extr/Adm control enabled.
  • Page 182 505E Digital Governor Manual 85018V1 MESSAGE 5 MEANING Extraction is Disabled Extraction control is disabled Extraction is Inhibited Extraction is inhibited and cannot be enabled Extraction is Enabled Extraction is enabled but not in control of actuator Extraction In Control...

  • Page 183: Alarms

    Manual 85018V1 505E Digital Governor Remote Extr/Adm Setpoint input is disabled by pressing the front panel NO key from the Remote Extr/Adm Status screen (screen 4), opening the Remote Extr/Adm Enable/Disable contact (if programmed), or selecting Remote Extr/Adm Disable from either Modbus communications link. See Table 5-14 for all possible Remote Extr/Adm control messages.

  • Page 184: Figure 5-17. Alarm Screen

    505E Digital Governor Manual 85018V1 Figure 5-17. ALARM Screen ALARM MESSAGES MEANING Speed Probe #1 Failed Speed probe #1 failure—(less than Failed Speed Level or less than 1Vrms) Speed Probe #2 Failed Speed probe #2 failure—(less than Failed Speed Level or less than 1Vrms) Cascade Input Failed Cascade input failure detected ( >...

  • Page 185: Trips

    Each individual alarm condition is available through the Modbus links to monitor the control status. A common alarm indication is also provided. Relay indications can be programmed to indicate a 505E common alarm, in addition to the dedicated Alarm Relay output.

  • Page 186: Speed, Casc, Aux, And Ext/Adm Dynamics Adjustments

    D = Derivative (determined by SDR and I) NOTE If an older type 505E is being replaced by a new 505E, the “ P & D ” terms may be the same, however, the “ I ” term should be reduced by a factor of 10 from the old 505E’s reset value to achieve the same control response.
  • Page 187 Manual 85018V1 505E Digital Governor In cases where a small change in the 505E’s output results in a large speed or load change (high mechanical gain) it may not be possible to take the 505E’s gains low enough to reach stable operation. In those cases the mechanical...
  • Page 188 Integral gain term (proportional gain may need to be increased also). On an initial startup with the 505E, all PID dynamic gain terms will require adjustment to match the respective PID’s response to that of its control loop.

  • Page 189: Figure 5-19. Typical Response To Load Change

    Manual 85018V1 505E Digital Governor 1. Increase Derivative Ratio (DR) to 100 (This is the default setting). 2. Reduce integral gain to minimum. 3. Increase proportional gain until system just starts to oscillate. 4. Record the system gain (G) and oscillation period (T).

  • Page 190: Chapter 6. Communications

    The two Modbus communication ports, as defaulted from the factory, are not configured to accept “write” commands. Although these ports are not configured, they continue to update all information to all registers. This allows the 505E to be monitored but not controlled from an external device. By simply connecting a monitoring device, configured to communicate through Modbus, this device can be used to monitor all the 505E’s controlling parameters, modes, etc.

  • Page 191: Figure 6-1. Ascii/Rtu Representation Of 3

    Program Mode and can be adjusted in the Service Mode, if required. The 505E control is programmed to function as a slave unit only. As a slave unit, the 505E will only respond to a transaction request by a master device. The 505E can directly communicate with a DCS or other Modbus supporting device on a single communications link, or through a multi-dropped network.

  • Page 192: Figure 6-2. Modbus Frame Definition

    505E Digital Governor Manual 85018V1 Figure 6-2. Modbus Frame Definition The Modbus function code tells the addressed slaves what function to perform. The following table lists the function codes supported by this control. Modbus Function Codes CODE DEFINITION REFERENCE ADDRESS...

  • Page 193: Port Adjustments

    505E as signed 16 bit integer values. Since Modbus can only handle integers, values that require a decimal point in the Modbus Master Device are multiplied by a scaling constant before being sent by the 505E. See Tables 6-7 & 6-8 for defaulted communication constants and ranges.

  • Page 194: Table 6-4. Maximum Modbus Discrete And Analog Values

    The holding coils available are listed in Table 6-5. Boolean Reads (Input Coils) Input coils are logical signals that are readable from, but not writable to, the 505E control. An example of a Boolean read value would be a turbine trip status indication.

  • Page 195: Table 6-5. Boolean Write Addresses

    505E Digital Governor Analog Writes (Holding Registers) Holding registers are analog values that are writable to the 505E control. These values can also be read from by a device performing error checking. An example of an analog write value would be a direct speed setpoint value as opposed to raise and lower setpoint commands.

  • Page 196: Table 6-6A. Boolean Read Addresses

    505E Digital Governor Manual 85018V1 ADDR DESCRIPTION ADDR DESCRIPTION 1:0001 Alarm—MPU #1 Failed 1:0060 Spare 1:0002 Alarm—MPU #2 Failed 1:0061 Spare 1:0003 Alarm—Cascade Input Failed 1:0062 Spare 1.0004 Alarm—Aux Input Failed 1:0063 Spare 1:0005 Alarm—KW Input Failed 1:0064 Shutdown Exits (Trip Indication) 1:0006 Alarm—Sync Input Failed...

  • Page 197: Table 6-6B. Boolean Read Addresses

    Manual 85018V1 505E Digital Governor ADDR DESCRIPTION ADDR DESCRIPTION 1:0119 Spare 1:0164 Contact In 2 (Closed) 1:0120 Extraction is Enabled 1:0165 Contact In 3 (Closed) 1:0121 Extraction is Active 1:0166 Contact In 4 (Closed) 1:0122 Extraction is in Control (not lmtd)

  • Page 198: Table 6-7A. Analog Read Addresses

    505E Digital Governor Manual 85018V1 ADDR DESCRIPTION UNITS MULTIPLIER 3:0001 Cause of last turbine trip * none none 3:0002 Speed Sensor #1 Input none 3:0003 Speed Sensor #2 Input none 3:0004 Actual Turbine Speed none 3:0005 Actual Speed (%) 3:0006...

  • Page 199: Table 6-7B. Analog Read Addresses

    Manual 85018V1 505E Digital Governor ADDR DESCRIPTION UNITS MULTIPLIER 3:0056 Extraction Scale Factor none none 3:0057 Extraction Input (Scaled) extr units extr scale factor 3:0058 Remote Extr Input (Scaled) extr units extr scale factor 3:0059 Spare 3:0060 Modbus Entered Speed Setpoint (fdbk)

  • Page 200: Table 6-7C. Analog Read Addresses

    505E Digital Governor Manual 85018V1 ADDR DESCRIPTION UNITS MULTIPLIER 3:0112 Contact Input 7 Configuration * none none 3:0113 Contact Input 8 Configuration * none none 3:0114 Contact Input 9 Configuration * none none 3:0115 Contact Input 10 Configuration * none...

  • Page 201: Table 6-9A. Control Status

    The controlling parameter status of the 505E uses two Analog Read registers (3:0070) & (3:0071) to identify the two parameters that are in control of the 505E. The analog register (3:0070) corresponds to the top line of the display. Analog register (3:0071) corresponds to the second line of the display.

  • Page 202: Table 6-9B. Control Status

    505E Digital Governor Manual 85018V1 CONTROL STATUS (Controlling Parameter—lower line of ‘CONT’ key display) VALUE......DESCRIPTION 1........Manual Admission Demand 2........Manual Extr/Extr Demand 3........Extr/Adm Control 4........Admission Control 5........Extraction Control 6........E/A Ctrl w/ Rmt Setpt 7........Adm Ctrl w/ Rmt Setpt 8........

  • Page 203: Table 6-11. Analog Output Configuration

    Manual 85018V1 505E Digital Governor Analog Read addresses 3:0094—0099 give the configuration value of the analog outputs, one to six in order. The configuration for the analog outputs are defined in the table below. ANALOG OUTPUT CONFIGURATION VALUE ......DESCRIPTION 1........Actual Speed 2.

  • Page 204: Table 6-12B. Relay Configuration

    505E Digital Governor Manual 85018V1 VALUE......DESCRIPTION (state relay options) 21........Shutdown Condition 22........Trip Relay (additional trip relay output) 23........Alarm Condition 24........Control Status OK 25........Overspeed Trip 26........Overspeed Test Enabled 27........Speed PID in Control 28........Remote Speed Setpt Enabled 29........

  • Page 205: Table 6-13. Contact Input Configurations

    Manual 85018V1 505E Digital Governor Analog Read addresses 3:0106—0117 give the configuration value of the contact inputs, one to twelve in order. The configuration for the contact inputs are defined in the table below. CONTACT INPUT CONFIGURATION VALUE ......DESCRIPTION 1........Generator Breaker 2.

  • Page 206: Specific Address Information

    505E Digital Governor Manual 85018V1 Analog Read addresses 3:0118-0119 give the configuration value of the Aux units and the Cascade units, in order. The configuration for the units are defined in the table below UNITS CONFIGURATION VALUE......DESCRIPTION 1........psi 2........
  • Page 207 (6015 / 100 = 60.15). A Directly Entered Cascade Setpoint (4:0002) of 61.5 would be sent across the link as 6150 and the 505E automatically divides the value by the Casc Scale Factor and uses the value of 61.5 as the setpoint desired.
  • Page 208 Modbus. The Emergency Shutdown command instantly takes the speed setpoint to zero and the HP & LP actuator currents to zero. Optionally the 505E can be configured to ignore this Emergency Shutdown command if it is desired to not allow the unit to be tripped through Modbus.

  • Page 209: Chapter 7. 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: •...

  • Page 210: Returning Equipment For Repair

    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: •...

  • Page 211: Replacement Parts

    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.

  • Page 212: Engineering Services

    505E Digital Governor Manual 85018V1 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 •...

  • Page 213: Technical Assistance

    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 Woodward Part Number and Revision Letter...

  • Page 214: Appendix . 505E Program Mode Worksheet

    505E Digital Governor Manual 85018V1 Appendix. 505E Program Mode Worksheet Governor Serial Number ______________________ Application ________________________________ Date ___________ TURBINE START SPEED SETPOINT VALUES Manual Start YES _____ NO _____ Overspeed Test Lmt (RPM) Automatic Start YES _____ NO _____ Overspeed Trip (RPM)
  • Page 215 Manual 85018V1 505E Digital Governor TURB PERFORMANCE VALUES DRIVER CONFIGURATION Use Decoupling ? YES _____ NO _____ Act #1 (HP) is 4-20mA? YES _____NO _____ Decouple Inlet (HP) ? YES _____ NO _____ Invert Driver Output ? YES _____NO _____...
  • Page 216 505E Digital Governor Manual 85018V1 AUXILIARY CONTROL RELAYS Use Auxiliary Control ? YES _____ NO _____ Use Relay #1? YES ____NO _____ Lost Aux Input Shutdown? YES_ ____ NO _____ Relay # 1 is Level Switch? YES ____NO _____ Use KW Input ?
  • Page 218 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.

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