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

Digital governor for steam turbines with single or split-range actuators
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Installation and Operation Manual
505 Digital Governor for Steam Turbines
with Single or Split-Range Actuators
Volume 2
Manual 85017V2C

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  • Page 1 Installation and Operation Manual 505 Digital Governor for Steam Turbines with Single or Split-Range Actuators Volume 2 Manual 85017V2C...
  • 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

    Keypad and Display....................39 Service Panel Modes....................40 Using the Service Mode ..................40 4. S ..........60 HAPTER ERVICE ROCEDURES Overview.......................60 The 505 Service Mode ..................61 Service Mode Blocks ....................70 Service Mode Worksheet Parameters ..............72 5. U PID S ..........92 HAPTER NDERSTANDING ETTINGS Overview.......................92...
  • Page 4 Mode ....................31 Figure 2-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode ..............34 Figure 3-1. 505 Keypad and Display ..............39 Figure 3-2. Software Structure Overview .............41 Figure 3-3. The Select Mode Level ..............42 Figure 3-4. Header Level..................42 Figure 3-5.

  • Page 5: 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 6 505 Digital Governor Manual 85017V2 Woodward...

  • Page 7: Introduction

    Manual 85017 Volume 2 is a dual purpose manual. It includes application- specific notes and 505 specific Service mode information. The first part of this volume gives users an idea of the 505 Digital Control’s capabilities, and how to apply them to a system. Typical applications are schematically shown and their functionality explained.

  • Page 8: Chapter 1. Peripheral Devices

    505’s programmed application. If the 505 is not configured to accept Modbus commands, the HMI functions as a system monitor only. If the 505 is configured to accept Modbus commands, all 505 Run Mode operations can be monitored and performed through it (start, stop, mode enable/disable, setpoint raise/lower).

  • Page 9: Figure 1-1. 505 Hmi Software

    The OpView or 505View can interface with the 505 through serial RS-232, RS- 422, or RS-485 communications. By using RS-422 or RS-485 communications, the HMI can be located up to 1220 m (4000 ft) from the 505 digital control. Digital Remote Final Driver...

  • Page 10: Figure 1-2. Digital Remote Final Driver

    505 Digital Governor Manual 85017V2 The 505’s actuator outputs have the capability of driving a 4–20 mA or 20–160 mA (200 mA max) proportional signal into an actuator coil. These 505 actuator output signals represent a demand signal equal to desired valve position (proportional).

  • Page 11: Figure 1-3. Real Power Sensor

    Woodward Real Power Sensors have terminals labeled “Output” and terminals labeled “KW Readout”. The “KW Readout” terminals provide a 4–20 mA signal proportional to real power which is used by and compatible with the 505 control. Thus the RPS terminals labeled “Output” are designed and typically compatible only to Woodward’s 2301 type of control.
  • Page 12 VAR/PF control, and a process control, integrated into one package. The 505 can be programmed to use the DSLC as a synchronizer only, or as a synchronizer and load control. The DSLC provides either phase match or slip frequency synchronizing, and ties into the unit automatic voltage regulator to match voltages before paralleling.

  • Page 13: Figure 1-4A. Digital Synchronizer And Load Control

    Manual 85017V2 505 Digital Governor Once the generator is synchronized the DSLC soft-loads the unit to the load setting determined by the mode of operation (base load, loadsharing, Process control). When commanded the DSLC can also soft-unload the unit and issue a breaker-open command at a set power level.

  • Page 14: Figure 1-4B. Digital Synchronizer And Load Control Functional Diagram

    A Hand-held Programmer (9905-292) is required and used by the DSLC to configure and calibrate it to the site specific application. The DSLC requires a power source of +24Vdc @ 1 A. The 505 power supplies can not supply this much power, thus an external power supply may be required.

  • Page 15: Figure 1-5. Dslc Interface Wiring

    Figure 1-5. DSLC Interface Wiring Master Synchronizer and Load Control (MSLC) The Woodward MSLC is a microprocessor based plant load control designed for use in three-phase electric power generation sites equipped with Woodward DSLCs which operate in parallel with the utility. The MSLC is a tie-line synchronizer, a plant import/export load control, reactive load control (power factor), and a master process control integrated into one package.

  • Page 16: Figure 1-6A. Master Synchronizer And Load Control

    505 Digital Governor Manual 85017V2 The MSLC’s baseload mode of operation allows an operator to set the plant to a specified load. A proportional or integrating control action can be used with this mode of operation. The integrating mode of operation can be used with systems tying to an unstable grid to allow the plant to control at a constant load and not vary based on grid frequency.

  • Page 17: Figure 1-6B. Master Synchronizer And Load Control Functional Diagram

    A Hand-held Programmer (9905-292) is required and used by the MSLC to configure and calibrate it to the site specific application. The MSLC requires a power source of +24 Vdc @ 1 A. The 505 power supplies can not supply this much power, thus an external power supply may be required.

  • Page 18: Chapter 2. Application Notes

    A combination of the Speed PID and its setpoint limits allow this PID to limit unit load. When used as a unit load limiter, it is recommended that the 505 be configured to sense and control only true generator load. If applying the 505 system to a soft grid (utility frequency varies greatly) it is recommended that unit load limiting be performed by the Auxiliary PID not the Speed PID.

  • Page 19: Example Applications

    Modbus communications. With this configuration when the Aux PID is enabled the Speed PID is disabled and tracks the Auxiliary PID’s output. To control or limit any of the listed parameters, the 505 must be programmed to accept an Auxiliary analog input signal representing that parameter’s level. The...
  • Page 20 505 Digital Governor Manual 85017V2 Example–To configure the 505 to perform a Turbine Exhaust pressure limiting function use Example 1, the “Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting” application for reference. With this example substitute exhaust pressure for inlet pressure and disregard any program settings specified to control pump or compressor discharge pressure.

  • Page 21: Figure 2-1. Pump Or Compressor Discharge Pressure Control With Turbine Inlet Pressure Limiting

    Figure 2-1 and described below. With this application pump/compressor discharge pressure control is performed within the 505 through the Cascade controller. Because the discharge pressure being controlled, typically affects many other plant processes, a plant Distributed Control System (DCS) may be used to monitor plant process conditions and set the Cascade setpoint position.
  • Page 22 Modbus commands, or the 505 service panel. The following list of notes is provided as a reference for application programmers to follow when configuring the 505 to achieve any of the control and limiting actions shown in figure 2-1: 505 Configuration Notes for Example 1 Operating Param: This is not a Generator application.
  • Page 23 In this example the turbine can be tripped by several devices, one of these devices is the 505 control. To provide feedback to the 505 control that the turbine is tripped, a contact from the trip string is wired into the External Emergency Shutdown input (TB12).

  • Page 24: Figure 2-2. Inlet Pressure Control With Automatic Synchronizing & Generator Power Limiting

    505 Digital Governor Manual 85017V2 Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Figure 2-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Woodward...
  • Page 25 With this application turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator.
  • Page 26 Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable inlet header pressure control. (Contact Input #3 Function: Casc Control Enable) The Cascade Input was inverted to allow the correct control action.
  • Page 27 When the plant-to-utility tie-line breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%.

  • Page 28: Figure 2-3. Exhaust Pressure Control With Generator Power Limiting And Plant Import/Export Limiting

    505 Digital Governor Manual 85017V2 With this application the Auxiliary control is programmed to be used as a limiter, and be automatically enabled when both the Utility Tie and Generator breakers are closed. When paralleled to the utility, if inlet header pressure demand, and/or...
  • Page 29 In order to limit generator load, the 505 control must be able to sense generator load. As shown in Figure 2-3 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW droop input.
  • Page 30 Analog input #1. (Analog Input #1 Function: KW/Unit Load Input) Because the RPS’s KW readout is self powered, the 505 back cover was removed and JPR11 installed. Generator load (when paralleled to the utility) is controlled by the Speed PID and programmed by selecting the KW/Unit load input.
  • Page 31 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-3 ). When this switch is closed the 505’s Synchronizing input is enabled and the DSLC’s automatic synchronizing function selected.
  • Page 32 When the plant to utility tie line/breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%.

  • Page 33: Figure 2-4. Plant Import/Export Control With Drfd Servo Interface

    With this RPS 12 mA represents zero power flow. Because of this feature the RPS #8272-726 can not, be used with the 505 to sense generator load/power.
  • Page 34 Manual 85017V2 This application uses a DSLC for synchronization only. Because the DSLC interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the DSLC, thus it is required that this input be programmed to receive the DSLC’s Speed Bias signal.
  • Page 35 Manual 85017V2 505 Digital Governor Dither is a low frequency ac current modulated on to the 505’s dc actuator– drive current to reduce stiction in linear type actuators. Because the 505’s actuator output is connected to the DRFD, dither was not required or used with this application.
  • Page 36 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-4 ). When this switch is closed the 505’s Synchronizing input is enabled and the DSLC’s automatic synchronizing function selected.

  • Page 37: Figure 2-5. Inlet Pressure Control With Isochronous Loadsharing Control In Island Mode

    Cascade control is disabled, and the 505 is switched to a Frequency control/loadsharing mode. A DSLC can only interface to a 505 through an analog input signal. The 505’s Analog Input #6 is the only analog input directly compatible with the DSLC, thus it is required that this input be programmed to receive the DSLC’s Speed Bias...
  • Page 38 DSLC. This synchronizing function/ input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 2-5 a panel mounted (DPST) switch is used with this application to select automatic synchronization in both the DSLC and 505.
  • Page 39 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-5 ). When this switch is closed the 505’s Synch/Load Sharing input is enabled and the DSLC’s automatic synchronizing function is selected.

  • Page 40: Figure 2-6. Import/Export Control Or Exhaust Pressure Control With Isoch Load Sharing In Island Mode

    505 Digital Governor Manual 85017V2 Example 6–Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode Figure 2-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode This application utilizes multiple turbine generators, and requires that all units have the capability to control different plant parameters depending on the status and health of each unit.
  • Page 41 Process Steam control (turbine exhaust pressure), and Loadsharing (used for plant import/export control or unit loadsharing). When a unit is switched to a Manual load control mode, its 505’s internal load setpoint determines unit load. This allows an operator to manually load or unload a unit to a set level if desired.
  • Page 42 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 2-6. 505 Configuration Notes for Example 6 OPERATING PARAM: This is a Generator application.
  • Page 43 The system operator can select automatic synchronization through the Auto-Synch select switch ( SW1 in Figure 2-6 ). When this switch is closed the 505’s Synchronizing input is enabled and the DSLC’s automatic synchronizing function selected.
  • Page 44 Example 7–Induction Generator Applications When the 505 is configured for induction generator applications, typically there are only two differences in the programming of the 505 verses programming for synchronous generator applications. The induction generator’s slip frequency must be taken into account. This is achieved by compensating for the slip frequency with the 505’s maximum Speed...

  • Page 45: Chapter 3. Operator Interface

    Chapter 3. Operator Interface Introduction Interface to the control may be performed through the 505’s service panel (located on the front of the control), remote switch contacts, analog inputs, meter readouts, relays, or a Modbus communications line to an operator interface device.

  • Page 46: Service Panel Modes

    505 Digital Governor Manual 85017V2 Service Panel Modes The 505 Service Panel operates in several access modes, each of which has a different purpose. These modes are: SERVICE, CONFIGURE, DEBUG, OS_FAULTS, and SYS_INFO. See Figure 3-2 , Software Structure Overview.

  • Page 47: Figure 3-2. Software Structure Overview

    Manual 85017V2 505 Digital Governor Figure 3-2. Software Structure Overview Woodward...

  • Page 48: Figure 3-3. The Select Mode Level

    505 Digital Governor Manual 85017V2 Select Mode Level This first level (below the Top Level/Root System block) contains the five different programmable service mode blocks. The five mode blocks are arranged within the first level as shown in Figure 3-3. Scroll left ( ) or right ( ) to display each mode.

  • Page 49: Figure 3-5. Block Level

    Manual 85017V2 505 Digital Governor Block Level The third level, the block level, is shown in Figure 3-5. The programmable service blocks containing the values to be monitored or changed are found at this level. Scroll down ( ) or up ( ) to get to a different block. Push CLEAR to get back to the header level.
  • Page 50 505 Digital Governor Manual 85017V2 This mode can also be used to make direct numeric entries. However, because this mode is intended to be used while the turbine is running, the Service Panel will accept the entry of numeric values for a block only if the proposed change is very small.
  • Page 51 Manual 85017V2 505 Digital Governor NOTE The headers and blocks are assigned their names by the application programmer; this is only an example. 5. The @ indicates which half of the split screen display that key entry will affect. Use the SELECT key to select either the top or bottom of the split screen display.
  • Page 52 505 Digital Governor Manual 85017V2 • To exit the mode, use the CLEAR key to get back to the header. Then press CLEAR again to get back to the Top Level/Root block. The values of all variables that were changed will then be stored in EEPROM.
  • Page 53 Manual 85017V2 505 Digital Governor Since configuring a control or viewing how a control is configured is such a commonly used mode the PRGM (program) key has been designed to take the user directly to step 4 below from anywhere in programmable service except DEBUG, OS_FAULTS, or SYS_INFO.
  • Page 54 The DEBUG mode is used to troubleshoot a system during development and is not intended for general use. It should be used only by properly trained Woodward personnel or when expressly authorized by Woodward Governor Company. Entry into the DEBUG mode requires a password.

  • Page 55: Figure 3-6. Debug Information Arrangement

    Manual 85017V2 505 Digital Governor The information in the DEBUG mode is arranged as shown in Figure 3-6. Scroll down to go from a MOE category to a MOE block; scroll up or down to go to another MOE block. Scroll left or right to go from a MOE block to a field of that MOE block, or from one field to another field of the same MOE block.

  • Page 56: Figure 3-7. Os_Faults Mode Information Arrangement

    505 Digital Governor Manual 85017V2 Figure 3-7. OS_FAULTS Mode Information Arrangement 1. To Enter the OS_FAULTS mode: The following message will be displayed when the system is at the select mode level. (MMMMMMMM = name of mode: SERVICE, CONFIGURE, DEBUG, OS_FAULTS or SYS_INFO) 2.
  • Page 57 Manual 85017V2 505 Digital Governor NOTE For password information see Appendix C at the back of this manual. If the password information is not in this manual, see the supervisor or equipment engineer. 4. Enter the password on the numeric keys and press the ENTER key. The header shown below will be displayed.
  • Page 58 If the display is not going to be used for a while, it is a good idea to return to the Top Level/Root display and permit the system to blank the display to save power and prolong its life. The meanings of the fault messages generated by the 505 System are shown in Chapter 7. Alarms Detected Header 1.
  • Page 59 If the display is not going to be used for a while, it is a good idea to return to the Top Level/Root display and permit the system to blank the display to save power and prolong its life. The meanings of the alarm messages generated by the 505 System are shown in Chapter 7. Clear Alarms Detected Header 1.
  • Page 60 505 Digital Governor Manual 85017V2 If any other key is pressed, the display will return to the header level and only the following message will appear. 3. To go from the Clear Alarms Detected header to the Top Level/Root display, press the CLEAR key.

  • Page 61: Figure 3-8. Sys_Info Mode Information Arrangement

    Manual 85017V2 505 Digital Governor Figure 3-8. SYS_INFO Mode Information Arrangement To enter the SYS_INFO mode: 1. The following message will be displayed when the system is at the select mode level. (MMMMMMMM = name of mode: SERVICE, CONFIGURE, DEBUG, OS_FAULTS or SYS_INFO) 2.
  • Page 62 505 Digital Governor Manual 85017V2 3. Press the ENTER key. The header shown below will be displayed. 4. Use the scroll left ( ) or scroll right ( ) key to select the desired SYS_INFO mode header. The header will display as shown below.
  • Page 63 Manual 85017V2 505 Digital Governor 2. Continue to Press scroll down ( ) to see more system information. The messages will appear as shown below. 3. From a system information message, to go back to the System Information header, press the CLEAR key.
  • Page 64 Top Level/Root display and permit the system to blank the display to save power and prolong its life. Download Configuration Header The Download function is to be used only by Woodward certified technicians. 1. While the Download Configuration header is displaying, use the scroll down ( ) key to enter this function.
  • Page 65 Manual 85017V2 505 Digital Governor 3. If the NO key is pressed the system will return to the Download Configuration header. If the YES key is pressed, the system will display the following message. 4. Push CLEAR to abort the configuration download, else download the configuration as described in Chapter 6 under Transferring Configuration Files.

  • Page 66: Chapter 4. Service Mode Procedures

    Service Mode Procedures Overview The service mode of the 505 control has the same easy to follow format as the program mode. The service mode can be used to customize the control to be more application specific. The parameters that are tuned in the service mode may affect system performance, caution is advised.

  • Page 67: The 505 Service Mode

    * before it can be adjusted. A work sheet is provided at the end of this manual, to document any changes for future reference. Figure 4-2 illustrates the 505 service menus and the questions/options available under each block.

  • Page 68: Figure 4-2B. Service Mode Blocks

    505 Digital Governor Manual 85017V2 Figure 4-2b. Service Mode Blocks Woodward...

  • Page 69: Figure 4-2C. Service Mode Blocks

    Manual 85017V2 505 Digital Governor Figure 4-2c. Service Mode Blocks Woodward...

  • Page 70: Figure 4-2D. Service Mode Blocks

    505 Digital Governor Manual 85017V2 Figure 4-2d. Service Mode Blocks Woodward...

  • Page 71: Figure 4-2E. Service Mode Blocks

    Manual 85017V2 505 Digital Governor Figure 4-2e. Service Mode Blocks Woodward...

  • Page 72: Figure 4-2F. Service Mode Blocks

    505 Digital Governor Manual 85017V2 Figure 4-2f. Service Mode Blocks Woodward...

  • Page 73: Figure 4-2G. Service Mode Blocks

    Manual 85017V2 505 Digital Governor Figure 4-2g. Service Mode Blocks Woodward...

  • Page 74: Figure 4-2H. Service Mode Blocks

    505 Digital Governor Manual 85017V2 Figure 4-2h. Service Mode Blocks Woodward...

  • Page 75: Figure 4-2I. Service Mode Blocks

    Manual 85017V2 505 Digital Governor Figure 4-2i. Service Mode Blocks Woodward...

  • Page 76: Service Mode Blocks

    505 Digital Governor Manual 85017V2 Service Mode Blocks Figure 4-2 shows the 29 service columns/blocks. The actual blocks that appear will vary with the program configuration. To enter the Service Mode, use the procedure described above. To use the Service mode, simply step through the blocks as described above and change the control features for your application.
  • Page 77 Manual 85017V2 505 Digital Governor Idle/Rated Ramp Settings—change the program or default settings of; idle rated rate; use ramp to idle; idle priority; Sync/Load Share Settings—change the program or default settings of; input bias gain; input bias deadband; lag-tau value;...

  • Page 78: Service Mode Worksheet Parameters

    This gives the operator the flexibility in the service mode to display or tune two different values by using the SELECT button . The service blocks contain information detailing each question and/or 505 program service option. Each question/option shows the default (dflt) value and the adjustable range of that parameter (shown in parentheses).
  • Page 79 Set to YES to permanently Hold the changes made to the Setpoint Fast Rate, the Entered Rate, and Underspeed settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Alarm Settings When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 80 When set to NO the generator load units are ‘KW’. When YES the units are set to ‘MW’ under the KW/9 key of the 505 front panel. This allows the 505 to display load units in terms of MW as opposed to KW.
  • Page 81 NO (Yes/No) Set to YES to permanently Hold the changes made to the Load Share Gain (%). To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Remote Speed Settings (only displayed if configured)
  • Page 82 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Speed Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Cascade Control (only displayed if configured)
  • Page 83 Manual 85017V2 505 Digital Governor SETPT FAST RATE (UNITS/SEC) dflt= xxx (0.01, 5000) This rate is defaulted to three times (3x) the setpoint ‘Slow Rate’. This value can be changed to a new value, however, the HOLD CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization.
  • Page 84 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Casc Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Woodward...
  • Page 85 NO (Yes/No) Set to YES to permanently Hold the changes made to the Setpoint Fast Rate, Entered Rate, and Rated Aux Setpoint. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Woodward...
  • Page 86 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Aux Settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Breaker Logic (only displayed if a generator)
  • Page 87 Set to YES to permanently Hold the changes made to the Gen Breaker Open Setpoint and Min Load Bias. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Valve Limiter When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 88 HOLD LIMITER CHANGES ? dflt= NO (Yes/No) Set to YES to Hold the changes made to the Entered Rate. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Local/Remote Functions (only displayed if configured)
  • Page 89 Manual 85017V2 505 Digital Governor EMERGENCY SHUTDOWN CLOSED ? (status indication only) RESET INPUT CLOSED ? (status indication only) RAISE SPEED INPUT CLOSED ? (status indication only) LOWER SPEED INPUT CLOSED ? (status indication only) CONT IN #1 CLOSED ?
  • Page 90 505 Digital Governor Manual 85017V2 FORCE RELAYS ? dflt= NO (Yes/No) Set to YES to allow testing of the relay outputs or associated external logic. Only active if the ‘Force Relays Enabled’ value is true (next display value- below). To be active, the unit must be shut down and the turbine speed less than 1000 rpm.
  • Page 91 Manual 85017V2 505 Digital Governor INPUT #1 OFFSET? dflt= 0.0 (-20, 20) INPUT #1 GAIN? dflt= 1.0 (0.00, 2.0) INPUT #2 OFFSET? dflt= 0.0 (-20, 20) INPUT #2 GAIN? dflt= 1.0 (0.00, 2.0) INPUT #3 OFFSET? dflt= 0.0 (-20, 20) INPUT #3 GAIN? dflt= 1.0 (0.00, 2.0)
  • Page 92 505 Digital Governor Manual 85017V2 Act1 Linearization When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change. The actuator linearization settings can be checked or verified by using the actuator stroke feature when the unit is shut down.
  • Page 93 Manual 85017V2 505 Digital Governor X-11 VALUE dflt= 100.0 (-5, 110) Input point #11 of the actuator linearization curve, in percentage. (Must be greater than the ‘X-10 Value’) Y-11 VALUE dflt= 100.0 (-5, 110) Output point #11 of the actuator linearization curve, in percentage.
  • Page 94 505 Digital Governor Manual 85017V2 X-9 VALUE dflt= 80.0 (-5, 110) Input point #9 of the actuator linearization curve, in percentage. (Must be between the ‘X-8 Value’ and the ‘X-10 Value’ settings) Y-9 VALUE dflt= 80.0 (-5, 110) Output point #9 of the actuator linearization curve, in percentage.
  • Page 95 Manual 85017V2 505 Digital Governor ENABLED WHEN LOCAL IS SELECTED ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus to be active even when LOCAL mode is selected. When NO, the Modbus commands are disabled when in LOCAL.
  • Page 96 505 Digital Governor Manual 85017V2 AUX SCALING FACTOR dflt= 1.0 (1.0, 100) Multiplier constant for all Auxiliary analog values sent over both Modbus links. When set to a value other than one (1.0), allows the Modbus device to scale inputs that are too small or to allow decimal places to be displayed.
  • Page 97 Manual 85017V2 505 Digital Governor MODBUS DEVICE NUMBER dflt= xx (1, 247) Enter a number from 1 to 247. This value is set in the program mode. TIME-OUT DELAY (SEC) dflt= 10.0 (0, 100) Sets the delay for no communication on the Modbus link before the link is considered failed and issues an alarm.

  • Page 98: Chapter 5. Understanding Pid Settings

    They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the 505 as follows: • P = Proportional gain (%) •...

  • Page 99: Proportional Response

    Manual 85017V2 505 Digital Governor Derivative, sometimes called “preact” or “rate”, is very difficult to draw an accurate analogy to, because the action takes place only when the process changes and is directly related to the speed at which the process changes.

  • Page 100: Figure 5-2. Open Loop Proportional And Integral Response

    If there is no error, then there is no Proportional effect. Integral Response Integral Gain as stated in the Woodward controls is repeats per minute (or Reset Rate). Therefore, a high amount of Integral gain (high number) would result in a large amount of Reset action.

  • Page 101: Proportional + Integral (Closed Loop)

    Manual 85017V2 505 Digital Governor Integral response is provided to eliminate the offset that resulted from straight Proportional control. Figure 5-2 shows how the controller action is Proportional to the measurement change, but as we saw earlier, this results in offset. The Integral (or Reset) action is a function of both time and magnitude of the deviation.

  • Page 102: Derivative Response

    505 Digital Governor Manual 85017V2 In Closed Loop, however (as opposed to Open Loop), as the measurement decays toward the Setpoint the Proportional action is taking place Proportionally to the measurement change, and the Integral action is decaying proportionately to the magnitude and duration of the deviation until the measurement reaches the setpoint at which time the Integral action is zero.

  • Page 103: Proportional + Derivative (Closed Loop)

    Proportional action to reduce stabilization time in returning the process to the setpoint after an upset. Derivative will not remove offset. Woodward Derivative is split into two working domains, Input dominant and Feedback dominant. The allowed values for DR range from 0.01 to 100. The most common derivative is Feedback dominant, it is automatically selected with an Derivative Ratio (DR) from 1 to 100.

  • Page 104: Figure 5-5. Closed Loop Proportional And Derivative Action

    505 Digital Governor Manual 85017V2 Figure 5-5. Closed Loop Proportional and Derivative Action Derivative (effects of settings) Figure 5-6. Derivative Setting Effects Woodward...

  • Page 105: Proportional + Integral + Derivative (Closed Loop)

    Manual 85017V2 505 Digital Governor Figure 5-6 shows the effect of different Derivative settings. The curves are relative since it depends on what type of control is desired in order to properly adjust Derivative time. For example, if minimum cycling is desired (as is shown here) then Derivative is added to the 1/4 decay cycle provided by Proportional until more than one cycle is removed and of course the 1/4 decay is destroyed.

  • Page 106: Controller Field Tuning General

    The value of the Derivative Ratio (DR) term can range from 0.01 to 100. In order to simplify adjustment of the dynamics of the 505, adjusting the integral gain value sets both the I and D terms of the PID controller. The DR term establishes the degree of effect the integral gain value has on the “D”...

  • Page 107: Figure 5-8. Typical Response To Load Change

    1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial startup with the 505, all PID dynamic gain terms will require adjustment to match the respective PID’s response to that of its control loop.
  • Page 108 505 Digital Governor Manual 85017V2 The following method can be used to achieve PID gain values that are close to optimum: 1. Increase Derivative Ratio (SDR) to 100 (Service Mode adjustment) 2. Reduce integral gain to 0.01 (Run Mode adjustment) 3.

  • Page 109: Chapter 6. Hardware/Operating System Faults

    General Most 505 problems which will be encountered are covered in the manual. Use the table of contents to locate the sections of the manual that may describe a specific problem.
  • Page 110 505 Digital Governor Manual 85017V2 “Reset caused by” “WATCHDOG TIMEOUT” “Reset caused by” “HALT MONITOR” “Reset caused by” “LOSS OF CLOCK” “Reset caused by” “SOFTWARE RESET” “Reset caused by” “TEST SUBMODULE RESET” All the above errors indicate a problem with the CPU module except the “Display Test Failed”...
  • Page 111 GND terminal (11) with input wiring disconnected, replace the 505. The operation of a contact input to the 505 can be checked by verifying that the voltage from the contact input’s (+) terminal measures 24 Vdc with respect to the contact input GND, terminal (11), when the external contact is closed.
  • Page 112 If an actuator hunts, or appears sticky, it may need dither (especially TM type). If the 505 control is not able to fully close or open the governor valves, check to make sure that the actuators are calibrated correctly, and valve linkage is correctly set.

  • Page 113: 505 Design Specifications

    Manual 85017V2 505 Digital Governor Appendix A. 505 Design Specifications Hardware Specifications Package Flush mount package Approximate physical size of 11” x 14” x 4” Environmental Category: Lloyd’s Type ENV2 NEMA: Type 4X or IEC 60529, IP 56 (applies only to front of flush mount package) Optional bulkhead Enclosure (approximate size: 20”...
  • Page 114 505 Digital Governor Manual 85017V2 Insulation Resistance/HiPot 4 V power supply: 707 Volts dc from power input to chassis ac/dc and HVac version: 2200 Vdc from power input to chassis Operating Temperature Without Enclosure (8923-439) = -25 to +65°C, still air, no external heat loads.
  • Page 115 Manual 85017V2 505 Digital Governor Speed Sensor Inputs 1. Two channels, jumper selectable between MPU input and Proximity input. 2. MPU input. a. Two isolated, independent channels. b. 1–25 VRMS input voltage range. c. 100–15000 Hz. d. Input impedance of approximately 1.5 kΩ...

  • Page 116: Software Specifications

    2. Isolated +24 V power provided for discrete inputs. 3. 2.5 mA draw on each input when contact is closed. 4. 18–25 Vdc external contact power may be used instead of the 505’s internal power supply. 5. Solid state relays may be used to drive any discrete input: a.

  • Page 117: 505 Service Mode Worksheet

    Manual 85017V2 505 Digital Governor Appendix B. 505 Service Mode Worksheet Governor Serial Number ______________________ Application ________________________________ Date ___________ For details on individual settings, refer to Chapter 4. SPEED CONTROL SETTINGS REMOTE SPEED SETTINGS (if configured) Rate to Min =...
  • Page 118 505 Digital Governor Manual 85017V2 REMOTE AUX SETTINGS (if configured) FORCE RELAY OUTPUTS (if shut down) Rmt N Mtchd Rte = UNITS/SEC Force Relays ? (troubleshooting only) Rmt Aux Max Rate = UNITS/SEC Force Rlys Enbl (status only) Min Rmt Aux Set =...
  • Page 119 Manual 85017V2 505 Digital Governor ACT1 LINEARIZATION PORT 2 SETTINGS (if configured) X-1 Value = Port 2 Link Err (status only) Y-1 Value = Exception Error (status only) X-2 Value = Error Code (status only) Y-2 Value = Use Mod 2 Trip...

  • Page 120: Appendix C. Password Information

    Service Mode Password When the display reads: The password for your control is: 1 1 1 1 Press the keys on the 505 front panel in this sequence followed by ENTER to gain access to the SERVICE mode. Debug Mode Password...

  • Page 121: Configure Mode Password

    OS_FAULTS Mode Password When the display reads: The password for your control is: 1 1 1 4 Press the keys on the 505 front panel in this sequence to gain access to the OS_FAULTS mode. Download Configuration Function Password When the display reads:...
  • Page 122 505 Digital Governor Manual 85017V2 Woodward...
  • Page 124 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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