Woodward 505HT Installation And Operation Manual
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Woodward 505HT Installation And Operation Manual

For pelton turbines 8200-1400, 8200-1401
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Product Manual 35116
(Revision -, 2/2019)
Original Instructions
505HT for Pelton Turbines
8200-1400, 8200-1401
Installation and Operation Manual

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  • Page 1 Released Product Manual 35116 (Revision -, 2/2019) Original Instructions 505HT for Pelton Turbines 8200-1400, 8200-1401 Installation and Operation Manual...
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    NFORMATION Information ..............................11 Controller Overview ............................. 11 Operator Control Panel ..........................12 Features ..............................12 Using the 505HT ............................12 505 Inputs and outputs ..........................13 Keypad and Display ............................ 15 Watchdog Timer/CPU Fault Control ......................17 2. H ...................
  • Page 4 Product Support Options ........................... 149 Product Service Options ........................... 149 Returning Equipment for Repair ....................... 150 Replacement Parts ............................ 151 Engineering Services ..........................151 Contacting Woodward’s Support Organization ..................151 Technical Assistance ..........................152 6. A ......153 HAPTER SSET...
  • Page 5 IAGRAM ........................195 EVISION ISTORY ........................196 ECLARATIONS The following are trademarks of Woodward, Inc.: Linknet Woodward The following are trademarks of their respective companies: Modbus (Schneider Automation Inc.) Illustrations and Tables Figure 1-1. 505 Keypad and Display ......................15 Figure 2-1.
  • Page 6 Released Manual 35116 505HT for Pelton Turbines Figure 4-19. General Configuration (7/9) Screen ..................87 Figure 4-20. General Configuration (8/9) Screen ..................89 Figure 4-21. General Configuration (9/9) Screen ..................91 Figure 4-22. Offline PID Screen ........................93 Figure 4-23. Offline PID Settings Screen ....................93 Figure 4-24.
  • Page 7 Table 2-16. Troubleshooting Fault Codes ....................38 Table 4-1. Mode Access by User Level ...................... 60 Table 4-2. 505HT Display Menus and Basic Functions ................63 Table 4-3. Manual (All Nozzles) Command Buttons and Parameters ............68 Table 4-4. Manual (Individual Nozzles) Command Buttons and Parameters ..........69 Table 4-5.
  • Page 8 Released Manual 35116 505HT for Pelton Turbines Table 4-38. Communications (Ethernet IP) Screen Configuration Values ..........126 Table 4-39. Communications (Default Gateway) Screen Configuration Values ........127 Table 4-40. Speed Switches Screen Configuration Values ..............128 Table 4-41. Nozzle Switches Screen Configuration Values ..............129 Table 4-42.

  • Page 9: Warnings And Notices

    Released Manual 35116 505HT for Pelton Turbines Warnings and Notices Important Definitions This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
  • Page 10 Released Manual 35116 505HT for Pelton Turbines IOLOCK. When a CPU or I/O module fails, watchdog logic drives it into an IOLOCK condition where all output circuits and signals are driven to a known de-energized state as described below. The System MUST be designed such that IOLOCK and power OFF states will result in a SAFE condition of the controlled device.

  • Page 11: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. 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.

  • Page 12: Regulatory Compliance

    The Real Time Clock Battery located on the CPU board is not to be recharged and is not user replaceable. Contact a Woodward Authorized Service Center if a replacement service is needed. This equipment must be installed in an area or enclosure providing adequate protection against high impact.

  • Page 13: Chapter 1. General Information

    It uses a built in graphical user interface (GUI) with multi-lingual menu driven screens to instruct site engineers on configuring the control to a specific application. The 505HT can be configured to operate as a stand-alone unit or in conjunction with a plant’s Distributed Control System.

  • Page 14: Operator Control Panel

    Operator Control Panel The 505HT is a field configurable hydro turbine control and operator control panel (OCP) integrated into one package. A comprehensive graphical operator control panel display and keypad is located on the 505HT’s front panel.

  • Page 15: 505 Inputs And Outputs

    Released Manual 35116 505HT for Pelton Turbines Calibration Mode – This mode is used to calibrate, tune and adjust certain parameters either while the unit is shutdown, or during turbine run time. A password is required to log into this mode.

  • Page 16: Table 1-3. Selectable Functions For 4-20Ma Analog Outputs

    Released Manual 35116 505HT for Pelton Turbines 17 - Remote Fault #2 41- Deflector Manual Close 18 - Remote Fault #3 42- Deflector Closed 19 - Remote Fault #4 43- Deflector Opened 20 - Remote Fault #5 44- Enable Remote Speed...

  • Page 17: Keypad And Display

    The control also communicates Servlink protocol (Woodward proprietary) via the Ethernet ports. Using Woodward’s Servlink to OPC Server tool any PC can use this connection to communicate to the control and relay OPC data to the various service tools that support the product.
  • Page 18 Released Manual 35116 505HT for Pelton Turbines A description of each key’s function follows. Hard Key Commands NUMERIC KEYPAD: These are available for entering numeric values or text strings directly into the control when a configurable or programmable edit field has been selected. The bottom row of keys have some special features.

  • Page 19: Watchdog Timer/Cpu Fault Control

    Released Manual 35116 505HT for Pelton Turbines BLACK KEYS Are soft-key functions that relate to the display indication located above them. They can be navigational or operational. These items do not require “Focus”, they are always available on that particular screen.

  • Page 20: Chapter 2. Hardware Specifications

    Flex 500 Description and Features The Flex505 controller is a significant upgrade to the existing 505 product line with enhanced CPU, Graphical display, communications, and I/O functions. Note: This controller supports expanded I/O options when using Woodward CAN distributed I/O nodes. Features •...

  • Page 21: Environmental Specifications

    For long term storage, the battery is specified to last > 5 years. The RTC battery is a replaceable lithium coin cell Woodward PN 1743-1017. Contact a Woodward Authorized Service Center if a replacement service is needed.

  • Page 22: Electromagnetic Compatibility (Emc)

    Power Inputs per Marine Type Approval test requirements. Outline Drawing for Installation The physical outline dimensions for the 505 control are shown below. See Woodward Reference drawing 9989-3210 for additional details if necessary. This 505 unit has the identical mounting hole pattern as the previous version, however the holes do not come through the front of this unit;...

  • Page 23: Figure 2-2. 505D Outline Drawing

    Released Manual 35116 505HT for Pelton Turbines Figure 2-2. 505D Outline Drawing Woodward...

  • Page 24: Input Power Specification

    Released Manual 35116 505HT for Pelton Turbines Input Power Specification Specifications (LV) LV Input Voltage range: 18-36 Vdc Input Power (max): < 77 W, 4.3 A max Output Voltage Holdup time: > 14 ms with 24 Vdc input voltage Isolation to other circuits: >...

  • Page 25: Communications (Ethernet)

    See the on-site Network Administrator to define an appropriate I/P address configuration. ETHERNET CABLES—Max cable length is 100 meters. To ensure signal integrity and robust operation, double shielded (SSTP) Cat5 Ethernet cables are required for customer installations. (Woodward PN 5417-394, 10 feet) Woodward...

  • Page 26: Communications (Can)

    SHIELD = Chassis GND Network Configuration Utility (AppManager) Woodward's AppManager™ software can be used to configure network setting and load Control software (GAP), HMI display software (QT), and operating system service packs. The AppManager utility can be downloaded from www.woodward.com/software.

  • Page 27: Table 2-4. Can Specifications

    Released Manual 35116 505HT for Pelton Turbines Network Topology: Daisy chain connections between multiple devices are recommended. Any drop cable connection of a device to the trunk line should be as short as possible and much less than 6 meters. It is recommended to design the network trunk to be less than 100 meters with a max cumulative drop length of less than 39 meters.

  • Page 28: Table 2-6. Can Cable Specifications

    Flex500 / 505 hardware products. However, the shield must also be directly terminated to chassis (Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be located at the master device end, as it exits the master device’s enclosure.

  • Page 29: Figure 2-3. Com1 Example Rs-485 Wiring

    RS-485 networks require termination at both ends with approx. 90–120 Ω impedance that matches the characteristic impedance of the cable used. Cable Note: Woodward cable 2008-1512 (3-wire) is a shielded, low capacitance 120 ohm cable that is designed for communications. This cable is also used for CAN communications.

  • Page 30: Communications (Service Ports)

    For debug use, a Woodward PN 5417-1344, USB to serial debug cable is required to attach this port to a PC. This port is to be used by trained Field Service personnel only! Table 2-9.

  • Page 31: Hardware - Terminal Blocks & Wiring

    Released Manual 35116 505HT for Pelton Turbines Hardware - Terminal Blocks & Wiring Back cover view with wiring label. Figure 2-4. 505 Back Cover Label Woodward...

  • Page 32: Terminal Block Connectors

    Released Manual 35116 505HT for Pelton Turbines Terminal Block Connectors Figure 2-5. Terminal Block Connectors Woodward...

  • Page 33: Hardware - Speed Sensor Inputs

    Separate terminals provided for MPU and Prox sensors • Isolated Prox Power (+24 Vdc) is provided with short-circuit protection • Woodward GAP block, diagnostics, and configuration support • GAP configurable update rates of 5 ms to 160 ms Table 2-10. Specifications (SSI)

  • Page 34: Hardware - Analog Inputs (4-20 Ma)

    Isolated Loop Power +24 V is provided with short-circuit protection • Fast AI channel #8 for special control functions • Woodward GAP block, diagnostics, and configuration support • GAP configurable update rates of 5 ms to 160 ms • GAP configurable for Loop power operation Table 2-11.

  • Page 35: Figure 2-7. Analog Input - Self-Powered Block Diagram

    Released Manual 35116 505HT for Pelton Turbines Figure 2-7. Analog Input – Self-Powered Block Diagram Figure 2-8. Analog Input – Loop-Powered Block Diagram Woodward...

  • Page 36: Hardware - Analog Outputs (4-20 Ma)

    Group isolated from other circuits • Capable of driving higher impedance loads up to 600 ohms • Woodward GAP block, diagnostics, and configuration support • GAP configurable update rates of 5 ms to 160 ms Table 2-12. Specifications (AO) Number of Channels:...

  • Page 37: Hardware - Actuator Outputs

    • Group isolated from other circuits • Capable of driving higher impedance loads • Woodward GAP block, diagnostics, and configuration support • GAP configurable update rates of 5 ms to 160 ms Table 2-13. Specifications (ACT) Number of Channels: (2) proportional drivers with source & return readbacks...

  • Page 38: Hardware - Discrete Inputs

    +24 V Contact Power with short-circuit and diode protection • Isolated power and discrete input group • Woodward GAP block, diagnostics, and configuration support • GAP configurable update rates of 5 ms to 160 ms • Time-stamping capability (1 ms) Table 2-14.

  • Page 39: Hardware - Relay Outputs

    Each Relay Output provides NO, COM, and NC contacts • Each Relay Output channel provides a coil voltage readback fault • Woodward GAP block, diagnostics, and configuration support • Contact isolation maintained at terminal blocks • ATEX approved version available using hermetically sealed relays •...

  • Page 40: Troubleshooting Fault Codes

    Verify PS(+) and PS(–) impedance to EARTH is > 10 MΩ RS-232 wiring checks • Verify the RS-232 wiring uses a high quality shielded communication cable. For example, Woodward 2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications wire. •...
  • Page 41 CAN wiring checks • Verify the CAN wiring uses a high quality, 3-wire, shielded communication cable. For example, Woodward 2008-1512 (Belden YR58684) or equivalent low capacitance, shielded communications wire. • Verify CAN network length is < max length spec for the baud rate being used •...
  • Page 42 Released Manual 35116 505HT for Pelton Turbines DI, Contact Power (CPWR) wiring checks • CPWR(+) is an output voltage, it should never be connected to any other supply. • To maintain node isolation, verify CPWR(–) is not shorted to PS(–).

  • Page 43: Chapter 3. 505Ht Control Description

    Description of IO The 505HT Control has a wide selection of functions to choose from a fixed amount of I/O (inputs and outputs). The control can be configured in the field to use the I/O to best fit the specific application. During the initial setup of the control, the functions that are needed for the specific application are selected and the necessary I/O points are assigned accordingly.
  • Page 44 Discrete input closed means that the deflector is closed. • Deflector Opened: if 505HT is configured to use two sensors to deflector Status this input is needed to inform the status of the deflector. Discrete input closed means that the deflector is opened.

  • Page 45: Control Outputs

    Released Manual 35116 505HT for Pelton Turbines • Enable Remote Level: This input enables the remote level control. In this control mode an analog input needs to be configured for Remote level. This control will work when the control is in level control mode.
  • Page 46 Released Manual 35116 505HT for Pelton Turbines Relay outputs Twenty relays outputs are available. All relay outputs can be used as normally open or normally closed (configurable). They’re all configurable and the available configuration is shown below: • Nozzle Position #1 to Nozzle Position #4: These are four outputs to nozzle position switch. Each nozzle position switch is individually configured.

  • Page 47: Functions

    505HT for Pelton Turbines Functions The functions of the 505HT for Pelton Turbines are described in detail in this section. The values that are in “quotes” can be configured for the specific application. Configuration of these values is discussed in greater detail in this manual.

  • Page 48: Figure 3-1. Nozzle Limit

    See Appendix F, Figure F-1 for additional detail of Nozzle Limit Speed Signal Processing The 505HT for Pelton turbines has two speed signal inputs, but only one speed signal is required. Using the second speed signal provides redundancy. If one speed signal fails, the control sends out an alarm but does not shut the unit down, if the other speed signal has not failed.

  • Page 49: Figure 3-2. Speed Deadband Function

    Released Manual 35116 505HT for Pelton Turbines The Control must be configured according to the type of speed signal being provided, the rated speed (rpm) of the turbine, the number of gear teeth (if applicable), and the system frequency (50 Hz or 60 Hz).
  • Page 50 Released Manual 35116 505HT for Pelton Turbines used. The Off-line/Isochronous algorithm controls the turbine speed to a set point determined by the operator. The droop setting does not affect off-line or isochronous control. For example, if the unit is off-line and the operator adjusts the set point to 95% rated speed, the Control will position the nozzles appropriately to control the turbine speed at 95% rated speed.

  • Page 51: Figure 3-3. Nozzle Position

    Released Manual 35116 505HT for Pelton Turbines A Remote Speed Reference can be used as well. There are three ways to enable the Remote Speed Reference: closing a digital input called “Enable Remote Speed”, or by enabling it via a Modbus Command, or via display command.
  • Page 52 Released Manual 35116 505HT for Pelton Turbines The on-line/Droop PID algorithm has a Feed Forward function that manipulates the PID feedback to accelerate the control’s response to set point changes. Feed Forward is only enabled when the control is using the On-line/Droop PID algorithm. This parameter should be handled carefully and left at its default value as much as possible.
  • Page 53 Released Manual 35116 505HT for Pelton Turbines If you are controlling the Pond Level (forebay level), be aware that increasing your Pond Level set point results in decreasing the Nozzle position, and vice-versa. Thus, the Raise input will result in moving the Nozzles in the closing direction.

  • Page 54: Figure 3-4. Pond Level Control Accuracy

    Released Manual 35116 505HT for Pelton Turbines Figure 3-4. Pond Level Control Accuracy The smaller the “Desired Control Accuracy” value is, the steeper the slope will be on the above graph. This will result in a very high “gain” on the Nozzle position, and small error fluctuations in the Pond/Tail Level will move the Nozzles very quickly.
  • Page 55 Released Manual 35116 505HT for Pelton Turbines When Creep inputs have been configured, the Control will start looking for the following conditions: • The unit is given a “Stop” command • The speed has decreased below the 2% • All nozzles are closed •...
  • Page 56 Released Manual 35116 505HT for Pelton Turbines An integrating signal is a 4 to 20 mA signal that positions a proportional valve, or pilot stage valve. The integrating signal is about 12 mA to center the proportional, or pilot stage, valve. When the current is less than 12 mA the valve moves one way, and when the current is greater than 12 mA the valve moves the other way.
  • Page 57 Released Manual 35116 505HT for Pelton Turbines When “Individual Nozzle Manual” mode is enabled (there’s one individual manual nozzle enable for each Nozzle) an individual nozzle demand is sent, via Raise and Lower Manual Nozzle #x. Direct setpoint can also be sent via Modbus or via display. The rate at which the manual position moves is configurable. The...
  • Page 58 Released Manual 35116 505HT for Pelton Turbines Small System Detection / Black Start When the turbine is in parallel to the grid it may be desirable to detect if the turbine is in island mode. This algorithm has this function. In order to do it monitors the turbine speed (when the turbine is in parallel to the grid) and verifies if both the speed and its derivative value are within configurable windows.
  • Page 59 Released Manual 35116 505HT for Pelton Turbines The nozzle load sharing should be thought in terms of water flow sharing, not actual nozzle demand. Therefore the nozzles x flow curves should be configured properly to achieve this goal. Nozzle Rotation The controller has a series of algorithms to rotate the used nozzles in order to make all nozzles to open/close even in case the load demand remains low.
  • Page 60 Released Manual 35116 505HT for Pelton Turbines Load Rejection The control provides a load rejection algorithm to detect a load surge upon a generator breaker opening in order to avoid turbine trip due to overspeed. This algorithm is triggered all the following conditions are present: •...
  • Page 61 TURBDAT_x.log, where x is an index that varies from 1 to 4. Therefore it will store the datalog files from the last four shutdown for later analysis. These files can be retrieved using a Woodward software called App Manager and can be opened/analyzed using Control Assistant.

  • Page 62: Chapter 4. 505Ht Display

    Released Manual 35116 505HT for Pelton Turbines Chapter 4. 505HT Display Program Architecture The 505 is easy to configure, due in large part to the menu-driven software. When the control is powered up and after the CPU self-test has been completed, the control displays the home screen and the CPU LED on the left side of the front panel should be green.
  • Page 63 Released Manual 35116 505HT for Pelton Turbines The Service user level allows the same commands as the Operator user level plus tuning of Service menu parameters and issuing of additional commands. The Configure user level allows the same commands and access as the Service user level plus tuning of Configuration menu parameters.

  • Page 64: Figure 4-1. Confirmation Screen

    Released Manual 35116 505HT for Pelton Turbines Breaker opened: Indicates the generator breaker is opened. Breaker Closed: Indicates the generator breaker is closed. Automatic screen changes Sometimes the screen can automatically change to another screen. The situations are described below.

  • Page 65: Home

    To program the control, navigate through the menus and configure the control features for the desired application. The menus and their basic functions are described below. Figure 4-3. Home Screen Table 4-2. 505HT Display Menus and Basic Functions Overview: An overview of the control. It shows the actual control mode, status of the each configured nozzle, deflector status, generator breaker, etc.

  • Page 66: Overview

    Released Manual 35116 505HT for Pelton Turbines Droop: To configure the Nozzle x Load curve Nozzles Mismatch: To configure all nozzles mismatches related to the configured Nozzles Level: To configure level control information. This button will be visible only when level...

  • Page 67: Figure 4-5. Nozzle Limit Popup

    Released Manual 35116 505HT for Pelton Turbines In the middle of the screen there is a turbine showing the position of the deflector. In the above example, the deflector is opened and it is being shown a green deflector at the right of the turbine. If the deflector is closed a red indication at the left of the turbine will be shown.

  • Page 68: Custom Trend

    Released Manual 35116 505HT for Pelton Turbines Custom trend This screen has a trend where the operator can choose what values want to monitor and the range of each one. The soft key “Settings” opens a screen to configure the trend. Pause the trend using the soft key “Pause”.

  • Page 69: Manual (All Nozzles)

    Released Manual 35116 505HT for Pelton Turbines Figure 4-7. Custom Trend Settings Screen Manual (All Nozzles) The purpose of this screen is to configure all parameters related to the manual control mode. The screen has command buttons and parameters which are described in table 4-3: Figure 4-8.

  • Page 70: Table 4-3. Manual (All Nozzles) Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-3. Manual (All Nozzles) Command Buttons and Parameters Enable Command Visibility: Always This command will enable the manual control mode User Level: Operator Disable Command Visibility: Always This command will disable the manual control mode...

  • Page 71: Manual (Individual Nozzles)

    Released Manual 35116 505HT for Pelton Turbines Manual (Individual Nozzles) The purpose of this screen is to configure all parameters related to the individual nozzle manual control mode. It will be many screens as configured nozzles. Each screen has the configuration for 2 different nozzles.

  • Page 72: Nozzle Test Screen

    Released Manual 35116 505HT for Pelton Turbines Rate 0.5 (0.01, 10.0) %/s Visibility: if specific nozzle is in use Rate that the individual manual ramp will use to increase or User Level: Service decrease the demand for the specific nozzle, when a pulse command is issued or when the setpoint is changed by Modbus command.

  • Page 73: Table 4-5. Nozzle Test Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-5. Nozzle Test Screen Command Buttons and Parameters Start Test Command Visibility: Always This command will start the test of this specific nozzle. User Level: Operator Stop test Command Visibility: Always This command will stop the test of this specific nozzle.

  • Page 74: Baseload Screen

    Released Manual 35116 505HT for Pelton Turbines Baseload Screen The purpose of this screen is to configure all parameters related to the baseload control mode. Figure 4-11. Baseload Screen Woodward...

  • Page 75: Table 4-6. Baseload Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-6. Baseload Screen Command Buttons and Parameters Rated Load 3.0 (0.0, 30000.0) MW Visibility: Always Enter the rated load of the generator in MW. CONFIGURATION MODE REQUIRED User Level: Configure Maximum Baseload Reference 3.0 (0.0, 30000.0) MW...

  • Page 76: Baseload Commands Screen

    Released Manual 35116 505HT for Pelton Turbines Baseload Commands Screen The purpose of this screen is to operate the baseload control mode. Figure 4-12. Baseload Commands Screen Woodward...

  • Page 77: Table 4-7. Baseload Commands Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-7. Baseload Commands Screen Command Buttons and Parameters Enable Command Visibility: Always This command will enable the baseload control mode. User Level: Operator Disable Command Visibility: Always This command will disable the baseload control mode.

  • Page 78: General Configuration (1/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (1/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-13. General Configuration (1/9) Screen Woodward...

  • Page 79: Table 4-8. General Configuration (1/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-8. General Configuration (1/9) Screen Command Buttons and Parameters Breakaway Limit 20.0 (0.0, 100.0) % Visibility: Always Value to be used during the startup of the turbine. Breakaway is the first step of the nozzles to force the turbine to break its initial User Level: Service inertia.

  • Page 80: General Configuration (2/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (2/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-14. General Configuration (2/9) Screen Table 4-9. General Configuration (2/9) Screen Command Buttons and Parameters Use Auto Raise Nozzle Limit...

  • Page 81: General Configuration (3/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (3/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-15. General Configuration (3/9) Screen Woodward...

  • Page 82: Table 4-10. General Configuration (3/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-10. General Configuration (3/9) Screen Command Buttons and Parameters Rated Speed *120.0 (10.0, 2000.0) rpm Visibility: Always Enter the rated speed of the turbine. CONFIGURATION MODE REQUIRED User Level: Configure Speed Deadband Select...

  • Page 83: General Configuration (4/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (4/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-16. General Configuration (4/9) Screen Woodward...

  • Page 84: Table 4-11. General Configuration (4/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-11. General Configuration (4/9) Screen Command Buttons and Parameters Use Baseload Control TRUE Visibility: Always Select if baseload mode will be used. CONFIGURATION MODE REQUIRED User Level: Configure Use Level Control FALSE Visibility: Always Select if level control mode will be used.

  • Page 85: General Configuration (5/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (5/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-17. General Configuration (5/9) Screen Woodward...

  • Page 86: Table 4-12. General Configuration (5/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-12. General Configuration (5/9) Screen Command Buttons and Parameters Rate to Increase / Decrease Speed 0.1 (0.001, 100.0) %/s Visibility: Always Rate that the control will use to increase or decrease the speed in offline mode.

  • Page 87: General Configuration (6/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (6/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-18. General Configuration (6/9) Screen Woodward...

  • Page 88: Table 4-13. General Configuration (6/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-13. General Configuration (6/9) Screen Command Buttons and Parameters Initial load in Droop Mode *5.0 (0.0, 100.0) % Visibility: Always Initial percent of load when the control is in Load droop mode or...

  • Page 89: General Configuration (7/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (7/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-19. General Configuration (7/9) Screen Woodward...

  • Page 90: Table 4-14. General Configuration (7/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-14. General Configuration (7/9) Screen Command Buttons and Parameters Include External trips in Trip Relay FALSE Visibility: Always Select to allow the external trip input(s) to de- energize the Trip Relay output. When unselected, an external trip contact input to...

  • Page 91: General Configuration (8/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (8/9) Screen The purpose of this screen is to configure some general parameters. Figure 4-20. General Configuration (8/9) Screen Woodward...

  • Page 92: Table 4-15. General Configuration (8/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-15. General Configuration (8/9) Screen Command Buttons and Parameters Open Breaker on Normal Stop FALSE Command Visibility: Always Select if a command to open the generator breaker will be issued when a Normal stop is in progress and the gate limit is at User Level: Service speed no load value for “Minimum Nozzle Limit Timeout”.

  • Page 93: General Configuration (9/9) Screen

    Released Manual 35116 505HT for Pelton Turbines General Configuration (9/9) Screen The purpose of this screen is to configure some general parameters. The operator can read some operation hours and configure (rewrite) the actual values in case of a 505´s replacement.

  • Page 94: Table 4-16. General Configuration (9/9) Screen Command Buttons And Parameters

    Released Manual 35116 505HT for Pelton Turbines Table 4-16. General Configuration (9/9) Screen Command Buttons and Parameters Rewrite Value FALSE Visibility: Configuration Mode Write the value (in hours) that will be written to the non-volatile memory when the Rewrite button is pressed.

  • Page 95: Offline Pid Screen

    Released Manual 35116 505HT for Pelton Turbines Offline PID Screen The purpose of this screen is to configure the offline PID. This screen has a live trend where it is possible to check the PV (Speed) in red, Setpoint in green, the PID output in blue and the Nozzle Limiter in pink.

  • Page 96: Online Pid Screen

    Released Manual 35116 505HT for Pelton Turbines Output / Limiter ranges: change the Minimum and Maximum range of the PID output and Nozzle Limiter. SP/PV Range: change the minimum and maximum range of the setpoint and PV (speed). Time span: change the time span of the trend.

  • Page 97: Figure 4-25. Online Pid Settings Screen

    Released Manual 35116 505HT for Pelton Turbines Table 4-18. Online PID Configuration Settings 0.52 (0.001, 50.0) Visibility: Always The Proportional Gain Input determines the gain of the proportional component of the block's response. User Level: Service 0.15 (0.001, 50.0) Visibility: Always The Integral Gain Input determines the gain of the integral component of the block's response.

  • Page 98: Baseload Pid Screen

    Released Manual 35116 505HT for Pelton Turbines Baseload PID Screen The purpose of this screen is to configure the Baseload PID. This screen has a live trend where it is possible to check the PV (Load) in red, Setpoint in green and the PID output in blue.

  • Page 99: Small System Detection Pid Screen

    Released Manual 35116 505HT for Pelton Turbines Output ranges: change the Minimum and Maximum range of the PID output. SP/PV Range: change the minimum and maximum range of the setpoint and PV (Load). Time span: change the time span of the trend.

  • Page 100: Figure 4-29. Small System Detection Pid Settings Screen

    Released Manual 35116 505HT for Pelton Turbines Table 4-20. Small System Detection PID Configuration Settings 1.6 (0.001, 50.0) Visibility: Always The Proportional Gain Input determines the gain of the proportional component of the block's response. User Level: Service 0.09 (0.001, 50.0)

  • Page 101: Step Test Screen

    Released Manual 35116 505HT for Pelton Turbines Step Test Screen The purpose of this screen is to help users to tune the PID´s of the control. It is possible to step positive or negative values for programmed time and send the setpoints back to the initial values. The step test screen is the same for all PID´s.

  • Page 102: Nozzle (1) Screen

    Released Manual 35116 505HT for Pelton Turbines Nozzle (1) Screen The purpose of this screen is to configure the Nozzles values. This screen has some individual nozzle parameters and it can have different quantity of parameters depending on how many nozzles has the turbine.

  • Page 103: Nozzle (2) Screen

    Released Manual 35116 505HT for Pelton Turbines Nozzle (2) Screen The purpose of this screen is to configure the Nozzles values. This screen has some individual nozzle parameters and it can have different quantity of parameters depending on how many nozzles has the turbine.

  • Page 104: Nozzle (3) Screen

    Released Manual 35116 505HT for Pelton Turbines Nozzle (3) Screen The purpose of this screen is to configure the Nozzles flows. This screen has some individual nozzle parameters and it can have different quantity of parameters depending on how many nozzles has the turbine.

  • Page 105: Table 4-24. Nozzles (3) Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-24. Nozzles (3) Screen Configuration Values Nozzle Position for Flow 0% *0.0 (0.0, 200.0) % Visibility: If Nozzle x is used Enter the nozzle (x) position necessary to 0% of flow. User Level: Service Nozzle Position for Flow 10% *10.0 (0.0, 200.0) %...

  • Page 106: Nozzle Rotation Screen

    Released Manual 35116 505HT for Pelton Turbines Nozzle Rotation Screen The purpose of this screen is to configure the automatic nozzle rotation and to provide a way to manually rotate the nozzles. This screen will be available if the turbine has more than one nozzle.

  • Page 107: Deflector Screen

    Released Manual 35116 505HT for Pelton Turbines Deflector Screen The purpose of this screen is to configure the deflector parameters. Figure 4-35. Deflector Screen Woodward...

  • Page 108: Table 4-26. Deflector Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-26. Deflector Screen Configuration Values Use deflector TRUE Visibility: Always Select to inform to 505 that the turbine has no deflector. This will prevent from some alarms and shutdowns from deflector fails.

  • Page 109: Deflector Commands Screen

    Released Manual 35116 505HT for Pelton Turbines Deflector Commands Screen The purpose of this screen is to Command the deflector. It is possible to enable and disable the manual control and manually open and close de deflector when manual control is enabled.

  • Page 110: Droop Screen

    Released Manual 35116 505HT for Pelton Turbines Droop Screen The purpose of this screen is to configure the droop curve (Nozzle x Load). Figure 4-37. Droop Screen Woodward...

  • Page 111: Table 4-28. Droop Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-28. Droop Screen Configuration Values Load % for Nozzle Demand 0% 0.0 (-100.0, 200.0) % Visibility: Always Enter the load % for nozzle demand of 0%. User Level: Service Load % for Nozzle Demand 10% 4.0 (-100.0, 200.0) %...

  • Page 112: Droop Commands Screen

    Released Manual 35116 505HT for Pelton Turbines Droop Commands Screen The purpose of this screen is to send the droop commands. Figure 4-38. Droop Commands Screen Woodward...

  • Page 113: Table 4-29. Droop Commands Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-29. Droop Commands Screen Configuration Values Go to Load Droop Command Visibility: Always Send the control to load droop, when the control is in droop mode. User Level: Operator and control in droop mode Go to Pos.

  • Page 114: Isolated Mode Commands Screen

    Released Manual 35116 505HT for Pelton Turbines Isolated Mode Commands Screen The purpose of this screen is to send the Isolated Mode commands. Figure 4-39. Isolated Mode Commands Screen Table 4-30. Isolated Mode Commands Screen Configuration Values Isolated Command Visibility: Always Send the control to isolated mode.

  • Page 115: Nozzles Mismatch Screen

    Released Manual 35116 505HT for Pelton Turbines Nozzles Mismatch Screen The purpose of this screen is to configure the nozzles and deflectors mismatch parameters. Figure 4-40. Nozzles Mismatch Screen Woodward...

  • Page 116: Table 4-31. Nozzles Mismatch Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-31. Nozzles Mismatch Screen Configuration Values Enable Minor Mismatch TRUE Visibility: If the specific nozzle is Enable the minor mismatch alarm for the specific nozzle. being used. User Level: Service Minor Mismatch value 3.0 (1.0, 100.0) %...

  • Page 117: Level Screen

    Released Manual 35116 505HT for Pelton Turbines Level Screen The purpose of this screen is to configure the level control parameters. Figure 4-41. Level Screen Woodward...

  • Page 118: Table 4-32. Level Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-32. Level Screen Configuration Values Head or Tail Level Control HEAD LEVEL CONTROL Visibility: Always Choose which level the level control will use. The options are Head level control or Tail level control.

  • Page 119: Level Commands Screen

    Released Manual 35116 505HT for Pelton Turbines Level Commands Screen The purpose of this screen is to send the Level control mode commands. Figure 4-42. Level Commands Screen Table 4-33. Level Commands Screen Configuration Values Enable Command Visibility: Always Enable the level control mode.
  • Page 120 Released Manual 35116 505HT for Pelton Turbines Go to Command Visibility: Always Command to send the level setpoint to the “Go to Value”. User Level: Operator and control in Level Control Go to Value *0.0 (-30000.0, 30000.0) eu Visibility: Always Value where the level reference goes when a “Go to”...

  • Page 121: Overspeed Test Screen

    Released Manual 35116 505HT for Pelton Turbines Overspeed Test Screen The purpose of this screen is to send the overspeed test commands. Figure 4-43. Overspeed Test Screen Table 4-34. Overspeed Test Screen Configuration Values Enable Command Visibility: Always Enable the overspeed test mode.
  • Page 122 Released Manual 35116 505HT for Pelton Turbines Time to Disable Test 1800.0 (1.0, 7200.0) s Visibility: Always Time to automatically disable the overspeed test. User Level: Service CAUTION: If the speed reference is greater than the overspeed level and the time expires, the turbine will shut down when overspeed test is automatically disabled.

  • Page 123: Remote Alarms Screen

    Released Manual 35116 505HT for Pelton Turbines Remote Alarms Screen The purpose of this screen is to configure the remote alarms. There are six remote alarms available on the control. Above an explanation of the first remote alarm, the other have the same configuration. The remote alarm will work only if one of the discrete inputs is configured to it.

  • Page 124: Communications (Serial Port) Screen

    Released Manual 35116 505HT for Pelton Turbines Communications (Serial Port) Screen The purpose of this screen is to configure serial communication port. Figure 4-45. Communications (Serial Port) Screen Table 4-36. Communications (Serial Port) Screen Configuration Values Use serial FALSE Visibility: Always Select if the serial port communication will be used.
  • Page 125 Released Manual 35116 505HT for Pelton Turbines Timeout 10.0 (0.5, 30.0) s Visibility: Always Enter the timeout for the serial port. User Level: Service ASC-II / RTU Visibility: Always Enter the ASC-II or RTU for the serial port. User Level: Service...

  • Page 126: Communications (Ethernet) Screen

    Released Manual 35116 505HT for Pelton Turbines Communications (Ethernet) Screen The purpose of this screen is to configure Ethernet communication ports. There are two available Ethernet links and they can be programmed on this screen. The screen has the same configuration for both ports, but the explanation will be made for just the port 1, as the port 2 has the same parameters.

  • Page 127: Communications (Ethernet Ip) Screen

    Released Manual 35116 505HT for Pelton Turbines Enable Boolean Write FALSE Visibility: Always Enable the Boolean write for the Ethernet port. If disable won’t be possible to write any Boolean value through this port. User Level: Service Link Error is Shutdown...

  • Page 128: Table 4-38. Communications (Ethernet Ip) Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Table 4-38. Communications (Ethernet IP) Screen Configuration Values ENET 1 ADDRESS 172.16.100.15 (0, 255) Visibility: Always Enter the integers corresponding to the network TCP/IP address. User Level: Service ENET 1 SUBNET MASK 255.255.0.0 (0, 255) Visibility: Always Enter the integer corresponding to the network subnet mask.

  • Page 129: Communications (Default Gateway) Screen

    Released Manual 35116 505HT for Pelton Turbines Communications (Default Gateway) Screen The purpose of this screen is to configure default gateway for the Ethernet ports communication. Figure 4-48. Communications (Default Gateway) Screen Table 4-39. Communications (Default Gateway) Screen Configuration Values Default Gateway 10.14.128.1 (0, 255)

  • Page 130: Speed Switch Screen

    Released Manual 35116 505HT for Pelton Turbines Speed Switch Screen The purpose of this screen is to configure the Speed Switches. There are six speed switches available on the 505. Figure 4-49. Speed Switches Screen Table 4-40. Speed Switches Screen Configuration Values High Value 1.0 (0.0, 200.0) %...

  • Page 131: Nozzle Switch Screen

    Released Manual 35116 505HT for Pelton Turbines Fail Safe State OPEN Visibility: Always Choose the fail-safe condition in case of both speed signal fail. User Level: Service Time to disable Fail Safe *20.0 (0.0, 300.0) min Visibility: Always Time to disable fail safe condition since both speed signals fail.

  • Page 132: Load Switch Screen

    Released Manual 35116 505HT for Pelton Turbines Decreasing Switch FALSE Visibility: Always Select if the switch is a decreasing switch. User Level: Service Decreasing Switch FALSE Visibility: Always Select to use fail safe condition. User Level: Service Fail Safe State...
  • Page 133 Released Manual 35116 505HT for Pelton Turbines High Delay *0.0 (0.0, 600.0) s Visibility: Always Enter the high delay time for the specific speed switch. User Level: Service Low Value 0.5 (0.0, 200.0) % Visibility: Always Enter the low value (in %) for the specific speed switch.

  • Page 134: Status Screen

    Released Manual 35116 505HT for Pelton Turbines Status Screen Figure 4-52. Status Screen The purpose of this screen is a screen where the operator can see some important information in a fast way. This screen is atomically opened after some time (if configured) or can be accessed on the menu (Status button).

  • Page 135: Analog Inputs Screen

    Released Manual 35116 505HT for Pelton Turbines Analog Inputs Screen The purpose of this screen is to configure the analog inputs of the control. The first screen showed is a summary of all analog inputs, and it is possible to check if the analog inputs has the signal failed, the description, tag, actual value and the engineering unit of this input (see below).

  • Page 136: Table 4-43. Analog Inputs Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines There are three information at the top of the page: the signal (in mA), the actual value (in the configured engineering unit) and if the signal is failed. The default values showed below are for the analog input #1.

  • Page 137: Speed Input Screen

    Released Manual 35116 505HT for Pelton Turbines Figure 4-55. Analog Inputs Calibrate Screen The adjustments for calibrate will be available if the control is in operator level or greater. Speed Input Screen The purpose of this screen is to configure the Speed inputs of the control.

  • Page 138: Table 4-44. Speed Signal 1 Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines Prox Signal Min (Volts): the minimum voltage sensed on the proximity probe speed input. This output is an average of ten samples with the minimum and maximum samples discarded. This output will be zero if the PROB_TYPE is not “Proximity Probe”.

  • Page 139: Contact Inputs Screen

    Released Manual 35116 505HT for Pelton Turbines Figure 4-57. Speed Sensor Open Wire Test Screen Contact Inputs Screen The purpose of this screen is to configure the contact inputs of the control. The first screen showed is a summary of the eighth first contact inputs, and it is possible to check the status, the description and tag of this input (see below).

  • Page 140: Figure 4-59. Contact Inputs Screen

    Released Manual 35116 505HT for Pelton Turbines Click on buttons at left of the screen to go to the specific contact input and configure it, if necessary or click on the “Contacts 9-16” or “Contacts 17-20” to see the others contact inputs. Below you can see the explanation of the contact input configuration screen.

  • Page 141: Analog Outputs Screen

    Released Manual 35116 505HT for Pelton Turbines Analog Outputs Screen The purpose of this screen is to configure the analog outputs of the control. The first screen showed is a summary of the six analog outputs, and it is possible to check is there is a fault in the each channel, the description, tag, actual value and the engineering unit (see below).

  • Page 142: Table 4-46. Analog Outputs Screen Configuration Values

    Released Manual 35116 505HT for Pelton Turbines There are three status of the analog output at the top of the page: Actual Value, readback (in mA) and the signal fault. The default values showed below are for the analog output #1. All other analog outputs have the same parameters.

  • Page 143: Relay Outputs Screen

    Released Manual 35116 505HT for Pelton Turbines Online Gain 1.0 (0.0, 50.0) Visibility: If channel is configured to Type the online gain of the actuator any actuator and actuator type is integral User Level: Service Offset 0.0 (-100.0, 100.0) Visibility: If channel is configured to...

  • Page 144: Figure 4-63. Relay Outputs Screen

    Released Manual 35116 505HT for Pelton Turbines Figure 4-63. Relay Outputs Screen There is the status of the relay output at the top of the page. The default values showed below are for the relay output #1. All other relay outputs have the same parameters.

  • Page 145: Actuator Outputs Screen

    Released Manual 35116 505HT for Pelton Turbines Actuator Outputs Screen The purpose of this screen is to configure the actuators outputs of the control. Figure 4-64. Actuator Outputs Screen There are three status of the actuator output at the top of the page. Actual output, source in mA and the readback.
  • Page 146 Released Manual 35116 505HT for Pelton Turbines mA at 100% Demand 20.0 (0.0, 25.0) mA Visibility: Always Set the mA value that corresponds to 100% demand. User Level: Service Actuator Type AO 01 Units Visibility: Always Choose if the actuator is Integral or proportional.

  • Page 147: Force Actuator Outputs Screen

    Released Manual 35116 505HT for Pelton Turbines Force Actuator Outputs Screen The purpose of this screen is to force the actuators outputs of the control. To access the screen the control needs to be in Calibration mode. Figure 4-65. Actuator Outputs Screen Procedure to force actuator: 1.

  • Page 148: Trip Summary Screen

    Released Manual 35116 505HT for Pelton Turbines Trip Summary Screen The purpose of this screen is to show the current trips on the control and the cause of the last trip. If a trip occurs this screen will open automatically.

  • Page 149: Alarm Summary Screen

    Released Manual 35116 505HT for Pelton Turbines Alarm Summary Screen The purpose of this screen is to show the current alarms on the control and the cause of the last trip. If an alarm occurs this screen will open automatically, if this function is enabled.

  • Page 150: Check Configuration Screen

    Released Manual 35116 505HT for Pelton Turbines Check Configuration Screen The purpose of this screen is to show the configuration errors on the control. Figure 4-68. Check Configuration Screen A list of all possible configuration errors are available on Appendix C.

  • Page 151: Chapter 5. Product Support And Service Options

    • An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission. A current list of Woodward Business Partners is available at www.woodward.com/directory.

  • Page 152: Returning Equipment For Repair

    All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-01-1205) on replaced parts and labor.

  • Page 153: Replacement Parts

    • The unit serial number, which is also on the nameplate Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. • Technical Support •...

  • Page 154: Technical Assistance

    505HT for Pelton Turbines Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...

  • Page 155: Chapter 6. Asset Management And Refurbishment Scheduling Period

    However, to take advantage of related product software and hardware improvements, we recommend that your product be sent back to Woodward or to a Woodward authorized service facility after every five to ten years of continuous service for inspection and component upgrades.

  • Page 156: Appendixa - Alarm List

    Released Manual 35116 505HT for Pelton Turbines Appendix A – Alarm List A list of all alarms and a brief explanation of each follows: Event ID Description Explanation Analog Input Fault - Channel 1 Channel is being used and its current falls below 2mA...
  • Page 157 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Mpu Open Wire - Channel 1 Channel is being used with MPU option and the internal wire test detects an open wire. Mpu Open Wire - Channel 2 Channel is being used with MPU option and the internal wire test detects an open wire.
  • Page 158 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Remote Level Signal Fail A given analog input channel is being used for this function and its current falls below 2mA or goes above 22mA Remote Fault #1 Discrete Input configured for this function closes (if an...
  • Page 159 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Major Nozzle6 Mismatch Nozzle #6 (if used) does not match within the “Major Mismatch Window” for more than the “Major Mismatch Delay” time Deflector Closed Mismatch Deflector is set to close, but no closed feedback is received within the “Deflector Closed Mismatch Delay”...
  • Page 160 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare...
  • Page 161 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare...
  • Page 162 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare...
  • Page 163 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare Alarm not used Spare...

  • Page 164: Appendixb - Shutdown List

    Released Manual 35116 505HT for Pelton Turbines Appendix B – Shutdown List A list of all shutdowns and a brief explanation of each follows: Event ID Description Explanation Emergency Stop Button Front Panel Emergency Button was pressed Calibration Mode Control is in Calibration Mode Configuration error There’s any configuration error.
  • Page 165 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Remote Fault #5 Discrete Input configured for this function closes (if an inverted input is used it has to be opened) Remote Fault #6 Discrete Input configured for this function closes (if an...

  • Page 166: Appendixc - Configuration Error List

    Released Manual 35116 505HT for Pelton Turbines Appendix C – Configuration Error List A list of all configuration errors and a brief explanation of each follows: Event ID Description Explanation DI#06 – Duplicated Function This discrete input has the same function of other DI DI#07 –...
  • Page 167 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation AI#02 – Duplicated Function This analog input has the same function of other AI AI#03 – Duplicated Function This analog input has the same function of other AI AI#04 – Duplicated Function This analog input has the same function of other AI AI#05 –...
  • Page 168 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Nozzle #4 ACT output not Control is configured to not use nozzle 4 but there’s necessary an AO configured for “Nozzle 4 Actuator” Nozzle #5 ACT output not Control is configured to not use nozzle 5 but there’s necessary an AO configured for “Nozzle 5 Actuator”...
  • Page 169 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Nozzle #4 Feedback not Control is configured to not use nozzle 4 but there’s necessary an AI configured for “Nozzle #4 Position Feedback” Nozzle #5 Feedback not Control is configured to not use nozzle 5 but there’s necessary an AI configured for “Nozzle #5 Position Feedback”...
  • Page 170 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Pond/Tail Level AI Not Configured “Use Level Control” is checked, but there’s no AI configured for “Pond/Tail Level” Baseload DI Not Necessary “Use Baseload Control” is unchecked, but there’s a DI configured for “Baseload Enable”...
  • Page 171 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Speed Bias Dig. Out. Not Speed Bias is not being used, but there’s a DO Available configured for either for “Speed Bias Enabled” or “Speed Bias Input Signal Fail”...
  • Page 172 Released Manual 35116 505HT for Pelton Turbines Event ID Description Explanation Man. Nlz3 Lower DI not Control is configured to not use nozzle 3 but there’s a Necessary DI configured for “Nozzle #3 Manual Lower” Man. Nlz4 Enable DI not Control is configured to not use nozzle 4 but there’s a...

  • Page 173: Appendixd - Modbus List

    Released Manual 35116 505HT for Pelton Turbines Appendix D – Modbus List The controller Modbus list, ordered by signal type (Boolean writes, Boolean reads, Analog Reads and Analog Writes) follows: Table D-1. Boolean Writes Address Description 0:0001 Emergency Shutdown 0:0002...

  • Page 174: Boolean Reads

    Released Manual 35116 505HT for Pelton Turbines Address Description 0:0039 Nozzle 3 Manual Mode Enable 0:0040 Nozzle 3 Manual Mode Disable 0:0041 Nozzle 4 Manual Mode Enable 0:0042 Nozzle 4 Manual Mode Disable 0:0043 Nozzle 5 Manual Mode Enable 0:0044...
  • Page 175 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0008 Alm - Analog Input Fault - Channel 7 1:0009 Alm - Analog Input Fault - Channel 8 1:0010 Alm - Actuator Fault - Channel 1 1:0011 Alm - Actuator Fault - Channel 2...
  • Page 176 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0053 Alm - Major Nozzle5 Mismatch 1:0054 Alm - Major Nozzle6 Mismatch 1:0055 Alm - Deflector Closed Mismatch 1:0056 Alm - Deflector Opened Mismatch 1:0057 Alm - Minor Nozzle3 Mismatch 1:0058...
  • Page 177 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0098 Alm - Spare 1:0099 Alm - Spare 1:0100 Alm - Spare 1:0101 Alm - Spare 1:0102 Alm - Spare 1:0103 Alm - Spare 1:0104 Alm - Spare 1:0105 Alm - Spare...
  • Page 178 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0143 Alm - Spare 1:0144 Alm - Spare 1:0145 Alm - Spare 1:0146 Alm - Spare 1:0147 Alm - Spare 1:0148 Alm - Spare 1:0149 Alm - Spare 1:0150 Alm - Spare...
  • Page 179 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0188 Alm - Spare 1:0189 Alm - Spare 1:0190 Alm - Spare 1:0191 Alm - Spare 1:0192 Alm - Spare 1:0193 Alm - Spare 1:0194 Alm - Spare 1:0195 Alm - Spare...
  • Page 180 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0233 Shutdown - Spare 1:0234 Shutdown - Spare 1:0235 Shutdown - Spare 1:0236 Shutdown - Spare 1:0237 Shutdown - Spare 1:0238 DI1 - Run/Stop Contact (closed) 1:0239 DI2 - Spd/Load Raise Contact (closed)
  • Page 181 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0278 Relay Out #5 ON 1:0279 Relay Out #6 ON 1:0280 Relay Out #7 ON 1:0281 Relay Out #8 ON 1:0282 LN2 - Relay Out #1 ON (future) 1:0283 LN2 - Relay Out #2 ON (future)
  • Page 182 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0323 Nozzle 5 Auto Test Enabled 1:0324 Nozzle 6 Auto Test Enabled 1:0325 Speed Bias Control Mode Enabled 1:0326 Spare 1:0327 Spare 1:0328 Spare 1:0329 Spare 1:0330 Spare 1:0331 Spare 1:0332...
  • Page 183 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0368 Off-Ln/Isoch Spd Ref - At Upper Limit 1:0369 On-Ln/Droop Spd Ref - Tracking 1:0370 On-Ln/Droop Spd Ref - At Unload 1:0371 On-Ln/Droop Spd Ref - At Rem Stpnt 1:0372 On-Ln/Droop Spd Ref - At Lvl Stpnt...
  • Page 184 Released Manual 35116 505HT for Pelton Turbines Address Description 1:0413 Nozzle 3 Manual Ref - At QT 1:0414 Nozzle 3 Manual Ref - At Auto Test 1:0415 Nozzle 4 Manual Ref - Tracking 1:0416 Nozzle 4 Manual Ref - At 0%...

  • Page 185: Table D-2. Analog Reads

    Released Manual 35116 505HT for Pelton Turbines Table D-2. Analog Reads Address Description Unit Multiplier 3:0001 An. Input 1 - EU Configurable 3:0002 An. Input 2 - EU Configurable 3:0003 An. Input 3 - EU Configurable 3:0004 An. Input 4 - EU...
  • Page 186 Released Manual 35116 505HT for Pelton Turbines Address Description Unit Multiplier 3:0044 Linknet - An. Input 4 - mA (Future) 3:0045 Linknet - An. Input 5 - mA (Future) 3:0046 Linknet - An. Input 6 - mA (Future) 3:0047 Linknet - An. Input 7 - mA (Future) 3:0048 Linknet - An.
  • Page 187 Released Manual 35116 505HT for Pelton Turbines Address Description Unit Multiplier 3:0089 Spare 3:0090 Spare 3:0091 Spare 3:0092 Spare 3:0093 Spare 3:0094 Spare 3:0095 Spare 3:0096 Spare 3:0097 Spare 3:0098 Spare 3:0099 Spare 3:0100 Spare 3:0101 Spare 3:0102 Spare 3:0103...
  • Page 188 Released Manual 35116 505HT for Pelton Turbines Address Description Unit Multiplier 3:0134 Analog Nozzle Limit (%) 3:0135 Nozzle Limit (%) 3:0136 MB Remote Speed Stpt (%) - fdbck 3:0137 MB Remote Baseload Stpt (MW) - fdbck 3:0138 MB Remote Level Stpt (EU) - fdbck...

  • Page 189: Table D-3. Analog Writes

    Released Manual 35116 505HT for Pelton Turbines Table D-3. Analog Writes Address Description Unit Multiplier 4:0001 Remote Speed Setpoint (%) 0.01 4:0002 Remote Baseload Setpoint (MW) 0.01 4:0003 Remote Level Setpoint (EU) 4:0004 Nozzle Average Limit Demand (%) 0.01 4:0005 Manual Nozzle Average Demand (%) 0.01...

  • Page 190: Appendixe - Trend Variables List

    Released Manual 35116 505HT for Pelton Turbines Appendix E – Trend Variables List See below the main variables list, to be used with control Assistant software. These variables are available to the user to do real time graphics. There are very variables on the control, but these are the more useful to the customer.

  • Page 191: Appendixf - Block Diagram

    Released Manual 35116 505HT for Pelton Turbines Appendix F – Block Diagram 52G BREAKER NOZZLE LIMIT RAISE NOZZLE LIMIT LOWER NOZZLE LIMITER START / STOP SHUTDOWNS & RESET NOZZLE LIMIT ALARMS RAMP BREAKAWAY LIMIT SPEED-NO- LOAD LIMIT MODBUS DEMAND DISPLAY...

  • Page 192: Figure F-3. Baseload Control

    Released Manual 35116 505HT for Pelton Turbines Figure F-3. Baseload Control START/STOP 52G BREAKER STEP TEST SPEED RAISE SPEED LOWER OFFLINE SPEED OFFLINE DEMAND REFERENCE OVERSPEED ENABLE OVERSPEED TEST TEST LOGIC SPEED NO LOAD REFERENCE ACTUATOR AVERAGE NOZZLE COMPENSATION POSITION...

  • Page 193: Figure F-5. Droop Feedback

    Released Manual 35116 505HT for Pelton Turbines ENABLE LOAD DROOP CTRL DROOP BASELOAD ENABLED FEEDBACK LEVEL ENABLED NOZZLE AVERAGE POSITION SIGNAL FAULT NOZZLE X LOAD CURVE CTRL GENERATOR POWER (AI) Figure F-5. Droop Feedback Figure F-6. Online Speed Control Woodward...

  • Page 194: Figure F-7. Nozzle Average Demand

    Released Manual 35116 505HT for Pelton Turbines 52G BREAKER ENABLE MANUAL CONTROL SELECT MANUAL START/STOP STEP TEST MANUAL DEMAND SPEED RAISE SPEED LOWER MANUAL SLECT REFERENCE ONLINE MODBUS NOZZLE DEMAND AVERAGE ONLINE DEMAND DEMAND SPEED BIAS IN USE DISPLAY DEMAND...

  • Page 195: Figure F-8. Nozzle Load Sharing

    Released Manual 35116 505HT for Pelton Turbines Figure F-8. Nozzle Load Sharing Figure F-9. Nozzle Auto / Manual Demand Woodward...

  • Page 196: Figure F-10. Deflector Logic

    Released Manual 35116 505HT for Pelton Turbines Figure F-10. Deflector Logic Woodward...

  • Page 197: Revision History

    Released Manual 35116 505HT for Pelton Turbines Revision History New Manual— • Woodward...

  • Page 198: Declarations

    Released Manual 35116 505HT for Pelton Turbines Declarations Woodward...
  • Page 199 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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