Woodward CONTROL-505D Product Manual
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Woodward CONTROL-505D Product Manual

Digital control for steam turbines
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Released
Product Manual 26839V2
(Revision D, 10/2021)
Original Instructions
505 Digital Control for Steam Turbines
Manual 26839 consists of 2 volumes (26839V1 & 26839V2)
Volume 2

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Summary of Contents for Woodward CONTROL-505D

  • Page 1 Released Product Manual 26839V2 (Revision D, 10/2021) Original Instructions 505 Digital Control for Steam Turbines Manual 26839 consists of 2 volumes (26839V1 & 26839V2) Volume 2...
  • 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

    Control Adjustments ............................ 83 Other Operating Problems .......................... 84 B. 505 D ................... 85 PPENDIX ESIGN PECIFICATIONS Hardware Specifications ..........................85 Software Specifications ..........................85 C. 505 S ................87 PPENDIX ERVICE ORKSHEET D. P ..................97 PPENDIX ASSWORD NFORMATION Woodward...
  • Page 4 PPENDIX SING NTERNAL IMULATION K. C ................129 PPENDIX USTOM ROCEDURE ......................130 PPENDIX ATALOGS The following are trademarks of Woodward, Inc.: ProTech Woodward The following are trademarks of their respective companies: Modbus (Schneider Automation Inc.) Pentium (Intel Corporation) Woodward...
  • Page 5 505 Digital Control for Steam Turbines Illustrations and Tables Figure 9-1. DSLC-2 ............................9 Figure 9-2. Configuration/Woodward Links/DSLC-2 ................... 10 Figure 9-3. Service Screen - DSLC-2 Power Parameters ................10 Figure 9-4. Service Screen - DSLC-2 Status Parameters ................11 Figure 9-5.
  • Page 6 Figure K-4. Automated File Collection Configuration ................134 Figure K-5. Automated File Collection Active ................... 135 Table 9-1. CAN Wiring from 505 to VS-II ....................12 Table 10-1. Example Application Summary ....................23 Table 11-1 Mode Access by User Level ..................... 47 Woodward...

  • Page 7: Warnings And Notices

    Be prepared to make an emergency shutdown when starting the engine, turbine, or other type of prime mover, to protect against runaway or overspeed with possible personal injury, loss of life, or property damage. Start-up Woodward...

  • Page 8: 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 9: Introduction

    505 Digital Control for Steam Turbines Introduction This volume of the manual contains application-specific notes, details on interfaces to other Woodward products and example configurations of typical steam turbine applications. This volume gives users an idea of the 505 Control’s capabilities, and how to apply them to a system.

  • Page 10: Chapter 8. Service Tools

    505 and a user PC or system HMI. The SOS program will run on the PC as a service and convert the 505 Woodward proprietary Servlink data to OPC data. The Control Assistant tool will connect as a client to the SOS server. Customers desiring to link to OPC data from the 505 will need to also connect to SOS.

  • Page 11: Chapter 9. Peripheral Devices

    Peripheral Devices Overview This chapter provides a brief explanation of other Woodward devices that can be easily integrated with the 505. By understanding the functionality of a peripheral device, a better understanding of the overall control configuration can be achieved.

  • Page 12: Figure 9-2. Configuration/Woodward Links/Dslc-2

    This is a “Woodward Link” device. To enable the Woodward Link feature select the check box on the screen above and enter the slave address and the IP address of the DSLC-2 device. The figure above shows the factory default IP addresses of the DSLC-2 and Ethernet port 3 of the 505.

  • Page 13: Varistroke Ii (Electro-Hydraulic Actuator)

    VariStroke II (Electro-Hydraulic Actuator) Figure 9-5. VS-II This is a “Woodward Link” device. The VariStroke-II is a linear electro-hydraulic actuator that is designed to provide the linear actuation force to operate steam turbine control valves or valve racks. This actuator can be directly networked with the 505 controller to reduce system complexity and wiring requirements.

  • Page 14: Figure 9-6. Configuration/Woodward Links/Vs-Ii

    Figure 9-6. Configuration/Woodward Links/VS-II To enable the Woodward Link feature select the check boxes on the screen above to enable the CAN1 Link and confirm usage of the VariStroke II actuator, then enter the Device ID. If an analog (4-20 mA) demand signal is going to be connected to the VariStroke in addition to the CAN link, then select the desired function for this signal (AI Backup is recommended).

  • Page 15: Mfr300 (Multi-Function Relay)

    A Servo Position Controller (SPC) can be used to interface the 505 digital controls to existing valve operators or Woodward actuators that are integrating in action or are not compatible with the 505 directly. The 505’s actuator outputs have the capability of driving a 4–20 mA or 0–200 mA (200 mA max) proportional signal into an actuator coil.

  • Page 16: Real Power Sensor

    4–20 mA output proportional to real power. Woodward manufactures two types of Real Power Sensors. The first type of RPS is designed to sense power flow in one direction only (0 to +5 A CT current only), and output a proportional 4–20 mA signal.

  • Page 17: Engine Generator Control Package/Load Sharing (Egcp-3 Ls)

    Woodward’s 2301 type of control. Woodward manufactured Real Power Sensors have a 2.5 Hz Low pass filter (400 ms lag time) on their output to filter out the high frequency noise typically created in a switch gear type environment. Thus if another vender’s watt transducer is used, verification that it has similar filtering criteria should be...

  • Page 18: Figure 9-13. Egcp-3 Control

    For the generator and bus the following parameters are provided: Hz, Vac, Amps, W, VA, VAR, PF, Phase, Voltage harmonics, Current harmonics, Negative Phase Sequence Voltage, Negative Phase Sequence Current. Available for selection at the 4–20 mA analog outputs: Synchroscope, Generator metering, Mains metering. Figure 9-13. EGCP-3 Control Woodward...

  • Page 19: Figure 9-14. Egcp-3 Ls Functional Diagram

    Released Manual 26839V2 505 Digital Control for Steam Turbines Figure 9-14. EGCP-3 LS Functional Diagram Woodward...

  • Page 20: Figure 9-15. Egcp-3 Ls Interface Wiring

    The following Generator Protections are available with the EGCP-3 LS: • Over/Under Voltage (59, 27) • Over/Under Frequency (81O, 81U) • Directional (Import/Export) Power (32)* • Negative Sequence Phase Overcurrent (46) • Negative Sequence Phase Overvoltage (47) • Phase Overcurrent (51) * • Directional VAR Woodward...

  • Page 21: Applying The 505 With Redundant I/H Or I/P Converters

    • Speed/Frequency Mismatch *—Inverse Time Protections implemented are according to IEEE C37.112 “Very Inverse” curves. For more information on Woodward’s EGCP-3 LS Control, please refer to Woodward manuals 26122 and 26194. Applying the 505 with Redundant I/H or I/P Converters The 505 can be applied in simplex or redundant actuator systems.
  • Page 22 Properly installed valves allow on-line converter replacement. For more information on Woodward’s Redundant CPC products, refer to manual 26448 and consult your sales representative about all CPC offerings.

  • Page 23: Chapter 10. Application Notes

    Plant or Tie line Import/Export Power • Process Temperature • Compressor Suction pressure • Compressor Suction Flow • Compressor Discharge pressure • Compressor Discharge Flow • Any process parameter related to unit load, inlet pressure/flow, or exhaust pressure/flow (depending on configuration) Woodward...

  • Page 24: Example Applications

    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. Woodward...
  • Page 25 Type Synchronous Generator Induction Generator Control Auxiliary Limiting Functions Auxiliary Control Cascade Control Synchronizing Load Sharing Frequency Control Control Inlet Pressure Control Modes Min Inlet Pressure Limiting KW Load Control KW Load Limiting Import/Export Load Control Import/Export Load Limiting Woodward...

  • Page 26: Figure 10-1. Pump Or Compressor Discharge Pressure Control With Turbine Inlet Pressure Limiting

    All 505 PID controller setpoints (Speed, Auxiliary, Cascade) may be changed through programmed raise and lower contacts, programmed 4–20 mA inputs, Modbus commands, or the 505 service panel. Woodward...
  • Page 27 505 initiated trip as follows: (Relays: Use Relay #4–Yes ; Relay #4 is a Level Switch?–No ; Relay #4 Energizes on–Trip Relay) Note that Relay #4 de-energizes on a trip condition (excluding external trip inputs) and Relay #3 energizes on a trip (shutdown) condition. Woodward...
  • Page 28 Auxiliary setpoint at any time the Auxiliary PID will take control of the governor valve and lower it to help preserve inlet header pressure. See the Service mode section of this manual, for information on related tunable values and rates. Woodward...

  • Page 29: Figure 10-2. Inlet Pressure Control With Automaticsynchronizing & Generator Power Limiting

    Released Manual 26839V2 505 Digital Control for Steam Turbines Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Figure 10-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Woodward...
  • Page 30 As shown in Figure 10-2 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW/unit load input. This allows generator load to be set and controlled by the Speed PID when paralleled to the utility during unit start-up and shutdown.
  • Page 31 The system operator can select automatic synchronization through the Auto-Synch select switch (switch SW1 in Figure 10-2). When this switch is closed the 505’s Synchronizing input is enabled, and the EGCP-3 LS’s automatic synchronizing function is selected. Woodward...
  • Page 32 Auxiliary PID will take control of the governor valve to limit generator load. Once system conditions demand unit load below that of the Auxiliary setpoint, the Cascade/Speed PIDs will again take control of generator load. Woodward...

  • Page 33: Figure 10-3. Exhaust Pressure Control With Generator Power Limiting And Plant Import/Export Limiting

    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. This gives a system operator full authority of when to transfer process pressure control to or from a letdown station or turbine bypass valve. Woodward...
  • Page 34 RPS #8272-726 cannot, be used with the 505 to sense generator load/ power. Please check with a Woodward certified distributor or factory for the correct RPS to use as a generator load sensor. This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed.
  • Page 35 After the unit is started, the Idle/ Rated or Auto Start Sequence functions, if programmed, can be used to assist ramping the control to a rated speed position. Alternatively, an operator can give a manual raise command to increase turbine speed as desired. Woodward...
  • Page 36 When programmed for this type of control action, the Speed PID is disabled when the Auxiliary PID is enabled, and can only limit the 505’s valve output signal if unit load reaches 100%. Also, the Auxiliary setpoint automatically tracks the PID’s input value when not in-control. Woodward...

  • Page 37: Figure 10-4. Plant Import/Export Control With Drfd Servo Interface

    With this configuration, when the generator is paralleled to the utility, the Speed PID controls governor valve position, instead of generator power. Thus 100% governor valve position is considered 100% unit load, no matter if system conditions are at rated or not. Woodward...
  • Page 38 LVDT mounted to the valve rack to feedback actual rack position. Because the 505 does not have a bipolar drive circuit, and cannot perform closed loop servo position control, a Woodward Digital Remote Final Driver (DRFD) was used to interface with the existing servo actuator. The integrating type of DRFD used, accepts a 4–20 mA valve demand signal from the 505, monitors actual valve position...
  • Page 39 Import/Export power before being enabled, the transfer to Auxiliary control is bumpless. Once enabled, the Auxiliary PID’s setpoint can then be positioned to the desired import or export level. Because of the 505’s configuration, this unit will automatically switch to Frequency control, upon the opening of the plant-to-utility tie breaker. Woodward...
  • Page 40 (505 LSS bus), not a generator load signal. Optionally, another Real Power Sensor could be used with this application to sense generator power and allow true unit load to be sensed and controlled. With this configuration, 100% governor valve position, is considered to be 100%-unit load, no matter what system conditions are. Woodward...

  • Page 41: Figure 10-5. Inlet Pressure Control With Isochronous Loadsharing Control In Island Mode

    EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal. When a Sync/LD Share analog input is programmed, the input is automatically enabled if the generator breaker input is closed, and the utility tie breaker input is open. Woodward...
  • Page 42 (Analog Input #6 Function: Synch/Load Share Input) With this configuration, the analog input’s range is defaulted to a certain gain value, for best performance, thus input’s 4 mA and 20 mA settings are not used and do not require programming. Woodward...
  • Page 43 +.1% of the desired frequency. Inlet header pressure (Cascade control) can be enabled any time after the utility tie and generator breaker contacts are closed. Cascade control can be enabled through a programmed contact, a Modbus command, or the 505’s service panel. Woodward...

  • Page 44: Figure 10-6. Import/Export Control Or Exhaust Pressure Control With Isoch Load Sharing In Island Mode

    The other units are used to control a plant export power level of 5 MW. Because the plant is contractually obligated to provide this level of power to the utility, and because it is more economical to make power than purchase it form the utility, a 5 MW plant export power level is desired. Woodward...
  • Page 45 This application uses Woodward EGCP-3 LSs and a MSLC to allow all units to communicate, share plant load, and control plant export power. The EGCP-3 LS is used on each unit, for synchronization and loadsharing.
  • Page 46 505 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%. The defaulted value is adjustable through the 505’s Service mode (Breaker Logic–Min Load Bias = 5). Woodward...
  • Page 47 Woodward EGCP-3 LSs can interface directly with a unit’s automatic voltage regulator. This allows units with EGCP-3 LSs to share reactive power as well as real power. This configuration also allows the MSLC to control plant power factor when the utility to tie breaker is closed.

  • Page 48: Chapter 11. Operator Interface

    The system operator uses the service panel to communicate with the 505 system. The service panel can be used only occasionally to communicate with the system, or it can continuously monitor user interface pages for the operator to view. Woodward...

  • Page 49: Service Panel Modes And User Levels

    The ADJUST arrows will change a selected Service parameter by 1%. Using the ADJUST arrows in combination with the SHIFT key will change the service parameter by 10%. The view of the Adjust button icon next to the value will change to show the up/down arrows as filled when the SHIFT key is pressed. Woodward...
  • Page 50 When making a direct entry of a negative number (for example, a sensor range of –50 to 200), enter the value first and then press the +/– key. When using the SERVICE mode, refer to the Service Mode worksheet in Appendix B. Woodward...

  • Page 51: Chapter 12. Service Menu Procedures

    Once logged in with an appropriate user level, parameters within the Service menus will become available for adjustment. See Figure 12.2 for an example of how to visually see that a parameter is authorized. A work sheet is provided at the end of this manual, to document any changes for future reference. Woodward...

  • Page 52: Figure 12-2. Authorized And Unauthorized Components

    Pressing Enter while on these pages will not navigate to these pages. This is different than the HOME page, where unused functions are completely removed to avoid confusion and simplify navigation. Figure 12-3 Service Menu (page 1) Woodward...

  • Page 53: Figure 12-4 Service Menu

    Pressure Compensation – Set system gain compensation vs inlet pressure points; view current system gain; Breaker Logic—change the program or default settings of; freq cntrl armed; sync window rpm; sync window rate; tie breaker open ramp; tie open rate; gen open setpoint; use min load; min load bias; Woodward...
  • Page 54 VariStroke II – CAN communication status; demand; position feedback; alarms; shutdowns; Manual Demand – Select manual valve demand usage; manual demand rate; timeout when inactive; Acceleration Limiter – Select acceleration limiter usage; adjust acceleration limiter PID gains; DSLC-2 – generator voltages, currents, real power, reactive power; communications link status Woodward...

  • Page 55: Service Mode Parameters

    0.0 (0.0, 20.0) When configured as a mechanical drive unit (not a Generator Application), this is the value of a speed deadband that can be configured in RPM. For a generator application, see ‘Frequency Deadband’ in the “Breaker Logic” Service menu. Woodward...
  • Page 56 Maximum and Minimum Speed Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. GENERATOR BREAKER OPEN DISABLE ? dflt= NO (Yes/No) When set to YES, the control will automatically disable the Remote Speed Setpoint whenever the Generator Breaker opens. Woodward...
  • Page 57 (0.01, 2000) Rate at which the speed set point will ramp from idle to rated speed when the turbine is considered HOT. This value is set in the program mode. USE RAMP TO IDLE ? dflt= YES (Yes/No) Woodward...
  • Page 58 Input point #2 of the pressure compensation curve, in engineering units. (Must be between the ‘Pressure 1’ value and the ‘Pressure 3’ value settings) Gain 2 dflt= *1.0 (0.65, 1.54) Output point #2 of the pressure compensation curve. Pressure 3 dflt= *50.0 (0.0, 10000.0) Woodward...
  • Page 59 This is the deviation, in Hz, from the configured rated speed of 50/60 Hz. It allows the center of the deadband to be adjusted for grid frequencies that are not exactly at 50 or 60 Hz. For example, if Woodward...
  • Page 60 SLOW RATE (UNITS/S) dflt= xxx (0.01, 1000) Normal set point rate of change. This value is set in the program mode. FAST RATE DELAY (SEC) dflt= 3.0 (0.0, 100) Delay, in seconds, before the ‘Fast Rate’ of change is selected. Woodward...
  • Page 61 (0.01, 1000) Rate the set point moves once the remote input and actual set point are matched. This is a maximum rate. Normally the set point will follow the remote input setting. This value is set in the program mode. Woodward...
  • Page 62 Note: Available as the last page of the “Auxiliary 2 Control” Service menu. 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. Woodward...
  • Page 63 CHANGES prompt must be set to YES to retain the change. If not, the value will return to the default on the next initialization. (Must be between the ‘Minimum Cascade Set Point’ and the ‘Maximum Cascade Set Point’ settings) Woodward...
  • Page 64 Rate the set point moves once the remote input and actual set point are matched. This is a maximum rate. Normally the set point will follow the remote cascade input setting. This rate is set in the Program Mode. Woodward...
  • Page 65 9 = Checksum Error 10= Garbled Message Press RESET to clear the port error. Ethernet Port 2 LINK STATUS (status indication only) Displays a green LED if the port is healthy. The `Time-out Delay` or port configuration may need to be adjusted. Woodward...
  • Page 66 LOCAL MODE ENABLED ? (status indication only) Indicates when the Local mode is enabled. When the indication is NO, remote mode is enabled. When YES, only “Local” commands are accepted by the control. See “Local/Remote” mode description in Volume 1. Woodward...
  • Page 67 When set to NO the unit will initialize into a ready to start mode if all shutdown conditions are clear. HP Linearization (can be configured as actuator output 1 or 2) This is configured by default as the Actuator 1 channel output. HP is the same functionality as “Actuator 1” in the older 2-line display non-extraction 505’s. Woodward...
  • Page 68 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. Woodward...
  • Page 69 Output point #8 of the actuator linearization curve, in percentage. 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) Woodward...
  • Page 70 LSS load percentage or the load analog input if configured. This number can be reset by pressing the ‘Reset Values’ soft key to reset all Operation Values to the “Rewrite Value” specified in this menu. Woodward...
  • Page 71 A green LED indicates the PID is controlling. PROCESS INPUT FAULT (status indication only) This is a status indication that the process value analog input is failed. A red LED indicates the process analog input fault is present. MANUAL DEMAND (status indication only) Woodward...
  • Page 72 This is the Derivative Ratio setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. Woodward...
  • Page 73 The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Parameter 5 (Orange) The configuration options are similar to that of Parameter 1. See Parameter 1 settings for a description of each option. Woodward...
  • Page 74 This is the Derivative Ratio setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters. Woodward...

  • Page 75: Chapter 13. Understanding Pid Settings

    (temporary overcorrection) in both increasing and decreasing directions. The application of brakes to fall behind the car in the first continuous lane or passing gear to get ahead of the car in the first continuous lane is derivative action. Woodward...

  • Page 76: Proportional Response

    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. Conversely, a low Integral gain (low number) would result in a slower reset action.

  • Page 77: Proportional + Integral (Closed Loop)

    The next highest curve is the Proportional action and follows the measured variable proportionately. The Integral curve adds to the Proportional curve resulting in a different valve position, thereby returning the process to the Setpoint. Woodward...

  • Page 78: Figure 13-3. Closed Loop Proportional And Integral Response

    1/4 decay ratio. If increased cycling occurs, the Integral must be turned off or the controller switched to “manual” if allowed to go too far. Ideally, the process should not continue to cycle after the setpoint has been reached as in the second curve from the bottom. Woodward...

  • Page 79: Derivative Response

    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 a Derivative Ratio (DR) from 1 to 100.

  • Page 80: Proportional + Derivative (Closed Loop)

    Notice offset still exists between the desired setpoint and the drooped control point that resulted from the load change. The top curve is the resultant controller output, Proportional plus Derivative. If an upset (momentary) had occurred rather than a load change, there would be no offset. Figure 13-5. Closed Loop Proportional and Derivative Action Woodward...

  • Page 81: Proportional + Integral + Derivative (Closed Loop)

    (duration) of the deviation. And the derivative temporarily over-corrects based on the speed at which the measurement moves in any direction. The resultant curve (at the top) shows a similar over-correction (in this case), but in addition the valve will stay at the new position required to keep the measurement at the setpoint. Woodward...

  • Page 82: Figure 13-7. Closed Loop Proportional, Integral And Derivative Action

    Auxiliary in), and can therefore prevent overshoot of the setpoint better than a feedback dominant controller. Although this response is desirable during a startup or full load rejections, it can cause excessive control motions in some systems where a smooth transition response is desired. Woodward...

  • Page 83: Controller Field Tuning General

    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. There are multiple dynamic tuning methods available that can be used with the 505’s PIDs to assist in determining the gain terms that provide optimum control loop response times. Woodward...
  • Page 84 Proportional gain = 0.35*Kc Integral gain = 0.76/T Deriv ratio = (5.2*T)/Integral Gain for fdbk dominant = (0.19*Integral Gain)/T for input dominant This method of tuning will get the gain settings close, they can be fine-tuned from this point. Woodward...

  • Page 85: Chapter 14. Hardware/Operating System Faults

    If the steam valve is blocked in this manner and the actuator output is steady but the turbine still hunts, then the problem is outside the governor. If an actuator hunts, or appears sticky, it may need dither (especially TM type). Woodward...

  • Page 86: Other Operating Problems

    From the (MANUAL SHUTDOWN) (PUSH YES OR NO) display, you cannot initiate a shutdown. If actual speed is less than the speed called for by the speed setpoint, check for droop (kW or speed). Droop causes the actual speed to be less than the speed reference. Woodward...

  • Page 87: 505 Design Specifications

    Microprocessor Motorola MPC5125 Microprocessor/25 MHz Interfacing to Woodward Service Tools All interfacing to service tools is done via Ethernet (RJ45) communications and can be accessed from any of the Ethernet ports. See the Appendices for instructions on connecting and using each of the service tools.
  • Page 88 Released Manual 26839V2 505 Digital Control for Steam Turbines The “nominal rate” listed is the fastest update rate, the worst case response would be twice the nominal rate. Woodward...

  • Page 89: 505 Service Mode Worksheet

    Speed Setpoint Maximum Rate RPM/s Minimum Speed Setpoint Maximum Speed Setpoint Remote Deadband Value Lag-Tau Value Use Minimum Load Hold Remote Speed Changes VALVE LIMITER Limiter Rate Entered Rate Limiter Maximum Limit HP Maximum at Start Shutdown at Maximum Hold Limiter Changes Woodward...
  • Page 90 Rate to Idle 3 (status) RPM/s Idle 3 Delay (status) PRESSURE COMPENSATION Selected Gain (status) Pressure 1 units Gain 1 Pressure 2 units Gain 2 Pressure 3 units Gain 3 Pressure 4 units Gain 4 Pressure 5 units Gain 5 Woodward...
  • Page 91 Use kW Droop? Entered Droop Setpoint AUXILIARY CONTROL (if configured) Slow Rate units/s Fast Rate Delay Fast Rate units/s Entered Rate units/s Droop Rated Auxiliary Setpoint units Threshold (Limiter) Threshold (Controller) PID Minimum Output Display Gauge Multiplier Hold Auxiliary Changes Woodward...
  • Page 92 Slow Rate units/s Fast Rate Delay Fast Rate units/s Entered Rate units/s Droop Rated Cascade Setpoint units Cascade Not Matched Rate units/s Maximum Speed Rate RPM/s Minimum Speed Setpoint Maximum Speed Setpoint Cascade Deadband Raise/Lower Cascade Only Use Minimum Load Woodward...
  • Page 93 Exception Error (status) Timeout Delay Error Code (status) Ethernet Port 3 Link Status (status) Exception Error (status) Timeout Delay Error Code (status) Servlink Socket 1 (status) Status (status) Level (status) Socket 2 (status) Status (status) Level (status) Socket 3 Woodward...
  • Page 94 Enable Contacts? Contacts Enabled (status) Enable Modbus? Port 1 Enable When Local Port 2 Enable When Local Port 3 Enable When Local Writes Enabled (status) KEY OPTIONS Use STOP Command Use TRIP from Remote View? ALARMS Trip is an Alarm Woodward...
  • Page 95 X-9 Value Y-9 Value X-10 Value Y-10 Value X-11 Value Y-11 Value HP2 Linearization X-1 Value Y-1 Value X-2 Value Y-2 Value X-3 Value Y-3 Value X-4 Value Y-4 Value X-5 Value Y-5 Value X-6 Value Y-6 Value X-7 Value Woodward...
  • Page 96 Total Run Time Hours (status) Disable Maintenance Aalrm Maintenance Interval Maintenance Alarm Peak Speed Reached Maximum Acceleration Reached ISOLATED CONTROL Setpoint units Process (status) Demand Remote Setpoint Enabled (status) Remote Setpoint Fault (status) Auto Control (status) Process Input Fault (status) Woodward...
  • Page 97 Screen Saver Delay Select Boot-Up Screen Auto Login as Operator? Operator Password CUSTOM TREND Settings Time Window Signal 1 (Red) Variable Y Maximum units Y Minimum units Width Show Axis Signal 2 (Green) Variable Y Maximum units Y Minimum units Woodward...
  • Page 98 VALUES FROM VARISTROKE II (HP VALVE) Varistroke II status information. (status) See Varistroke II manual for details. MANUAL DEMAND Use Manual Demand Manual Demand Rate Timeout When Inactive ACCELERATION LIMITER Use Acceleration Limiter Proportional Gain Integral Gain Derivative Ratio Woodward...

  • Page 99: Appendix D. Password Information

    “Service” User Level Password Login as Service: Login: Service Password: wg1112 “Configure” User Level Password Login as Configure: Login: Configure Password: wg1113 “ServiceUser” User Level Password Login as ServiceUser (no autofill key available, must be entered manually): Login: ServiceUser Password: ServiceUser@1 Woodward...

  • Page 100: Appendix E. Servlink-To Opc Server (Sos) Tool

    The Woodward SOS Servlink OPC server ("SOS") provides an OPC interface for Woodward controls. It runs on a Windows PC that accesses data on controls using the Woodward proprietary Servlink protocol through an Ethernet connection. Woodward OPC client applications, such as Monitor GAP and Control Assistant connect to SOS by selecting a 'Servlink OPC server' connection.

  • Page 101: Connecting A Pc/Laptop To The Control

    The Default IP for Ethernet 1 = 172.16.100.15 (subnet = 255.255.0.0) All information in the communication link between the 505 and the PC is done via a Woodward Servlink connection (using the SOS tool). It is recommended to initially launch this tool independently to establish a healthy communication link.

  • Page 102: Figure E-4. Sos - New Session Box

    Figure E-5. SOS - Enter 505 TCP/IP address The SOS program will locate the control and establish a Woodward Servlink connection between the control and your PC. This will take a few seconds to establish, the dialog box should now look like this (with the IP address being equal to what you typed in above).
  • Page 103 The Control ID can be changed via SOS by right clicking the session and selecting “Set ControlId” Type in the new Control ID and press ‘Set’ to commit the change. The new Control ID can be used with Control Assistant Trend Scripts, etc. Woodward...

  • Page 104: Appendix F. Control Assistant-Software Interface Tool

    Viewing Datalog files Prior to installing Control Assistant, you must install the Microsoft .net framework program which is available on the Woodward website (www.woodward.com). This will install some operating system library files that are used by Control Assistant. Installing Control Assistant License Agreement &...

  • Page 105: Figure F-2. Control Assistant Install Window

    Define the desired directory to save Control Assistant and press ‘Next’. It is preferable to use the default, as it will keep all Woodward Software in a common folder. If the program folder field is blank, type in “Woodward” and the install will create a program folder named Woodward.

  • Page 106: Using Control Assistant

    The Factory Default tunables are useful when training personnel on how a spare unit will look when initially powered, and then step through the procedure below to install site specific settings. To launch Control Assistant: Under Start / All Programs / Woodward / Control Assistant 4 Click on Control Assistant 4...

  • Page 107: Figure F-7. Dialog For Servlink Opc Connection

    Windows application that provides a powerful and intuitive interface. The menu structures are familiar to Windows users. Variable navigation is provided through the Explorer window similar to the Explorer in Windows. This tool will look very familiar to users with experience using Woodward’s Watch Windows products.

  • Page 108: Figure F-9. Control Assistant - Retrieve Tunable Dialog Box

    If the 505 TRIPPED LED was ON (Trip is present) a confirmation box will appear that Lock IO was issued. If the 505 TRIPPED LED was OFF (no trips present) then the confirmation box will state it was not allowed Woodward...

  • Page 109: Figure F-10. Control Assistant - Send Tunable Dialog Box

    Use File/Open to open a previously saved trend script file (if you have one). To create new trends, the user will need some understanding of how Woodward’s GAP software is constructed as well as some specific knowledge of the 505 application software. If the user is not familiar with GAP they should limit their use to existing trend script files.

  • Page 110: Figure F-11. Control Assistant - Speed Control Trend Script

    Click File > Open script as a template… > Select the Trend Script Control Assistant will then pull up a list of all the controls available in SOS. Select the control you would like to apply the Trend Script to. Woodward...

  • Page 111: Appendix G. Appmanger Service Tool

    AppManger Service Tool File Management with App. Manager AppManager is a Windows based remote access tool for Woodward controls. The 505 is loaded with a service that allows it to interface with AppManager. AppManager is used to manage the applications on the 505 and provide access to operating system information.

  • Page 112: Figure G-2. App Manager License Agreement Window

    To install App Manager, select “I accept the terms in the license agreement”. Once this has been selected, select Next to continue the installation. Figure G-3. App Manager Installation Choose the desired folder in the ‘Start Menu’ to save the shortcuts. Woodward...

  • Page 113: Figure G-4. App Manager Install Complete

    For user already familiar with this tool the only new feature is the ability to access the GUI files. For complete information on this tool use the help menu To launch App Manager: Under Start / All Programs / Woodward / AppManager Click on AppManager You should see the following dialog box appear –...

  • Page 114: Figure G-6. Dialog For App Manager Connection

    Control Information. The figure below shows an example of the all the information available here. This is a useful place to obtain embedded software part numbers, memory usage, Ethernet IP assignments and total hardware run hours (power up time). Woodward...

  • Page 115: Figure G-8. Appmanager Control Info Window

    The application panel has two views - the control application panel has a white background while the GUI application window has a maroon background. To toggle between the panels use the swap button on the far right side (the second button down from the top). Figure G-9. AppManager Control (GAP) Application Panel Woodward...

  • Page 116: Figure G-10. Appmanager Gui Application Panel

    If this occurs the user must first delete the file on the control before the new one can be transferred. Woodward typically adds a revision or a build number to the end of the file name so that any updates can be added to the control and the previous revisions will still be available.
  • Page 117 AppManager is the tool that is used if a service pack needs to be installed to update the OS or the real- time process that executes the GUI application. Typically, this will only be done by Woodward representatives or a service bulletin that directs the user through the process.

  • Page 118: Appendix H. Configuring Network Tcp/Ip Addresses

    The ENET 1, ENET 2, and ENET 3 configuration refer to the physical Ethernet connections on the unit. ENET 4 is reserved and is not configurable through the front panel. ENET 3 ENET 2 ENET 1 Figure H-2. Ethernet Port Layout (Ports on Side) Woodward...
  • Page 119 Once a new gateway address has been entered, the “Set Gateway” button must be pressed in order to send the new gateway to the control. • Once set, the new gateway will be displayed at the top of the pop-up page. Woodward...

  • Page 120: Appendix I. Remoteview Tool

    When the installation file is executed, the following welcome window will appear: Figure I-2. Installation Welcome Window Select “Next” to continue. The Installation Folder window will open. A default installation folder will be shown. If a different installation folder is needed, click the “Browse…” button to select the new folder. Woodward...

  • Page 121: Figure I-3. Installation Folder Window

    Select “Next” to continue. The Start Menu shortcuts window will open. A default location in the Woodward program folder will be shown. If a different Start Menu location is needed, type the new location in the window or select one of the locations presented in the list.

  • Page 122: Figure I-5. Installation Start Menu Shortcuts Window

    Configuration of the installation is complete, and the actual installation process will begin. A window will open showing the progress of the installation. If prompted to do so, give the installation file permission to make changes to the PC. The following window will open when installation is complete. Woodward...

  • Page 123: Figure I-7. Installation Complete Window

    Click “Finish” to close the window. The Remote View tool is now ready for use. Remote View Configuration To start the Remote View tool, go to the Start Menu and select 505 Remote View from the Woodward folder (or in the alternate folder specified at installation). The configuration window will open. This window has the following sections: •...

  • Page 124: Figure I-9. Control Selected In The Control List

    Displaying the applications requires login to the control. When the “Get app list” button is clicked, the login window will open. Figure I-10. Login Window with Fields for User Name and Password Woodward...

  • Page 125: Figure I-11. An Application Selected In The Application List

    505 front panel, but with the right and bottom physical buttons hidden. The Full setting shows the tool as just the screen from the front panel (all physical buttons hidden). Click the “Apply” button to confirm the scale and panel type. Woodward...

  • Page 126: Figure I-12. Default View Of The Tool

    Released Manual 26839V2 505 Digital Control for Steam Turbines Figure I-12. Default View of the Tool Figure I-13. Simple View of the Tool Woodward...

  • Page 127: Figure I-14. Full View Of The Tool

    The following figure shows “Demo” entered as the name for the current settings. Figure I-15. Entering a Name for the Current Settings After clicking “Save”, the settings file will be displayed in the list, as shown in the following figure. Woodward...

  • Page 128: Figure I-16. A New Settings File Entered In The Predefined Settings List

    Get the application list for the control (requires login) The Remote View tool is opened by selecting an application in the configuration window and clicking “Launch”. Alternately, the Remote View tool can be opened by selecting a properly configured settings file from the configuration window. Woodward...

  • Page 129: Figure I-17. Remote View Tool (Default Setting) After Opening From The Configuration Window

    The configuration window can be opened at any time by clicking the gear button at the top right corner of the tool. The Remote View tool can be closed by clicking the X button at the top right corner of the tool. Woodward...

  • Page 130: Appendix J. Using 505 Internal Simulation Mode

    3. Configure the ramp rates at rate times as a fraction of what you want (for example for a 4 hour idle delay use 0.24 minutes instead of 240 min) 4. Exit the configuration mode and re-login as ServiceUser 5. Simulate a start Woodward...

  • Page 131: Appendix K. Custom Tag Name Procedure

    7) Open the appropriate GUI application folder, and download the “custom_tags.ini” file 8) Select “Transfer Files to the Current Control” 9) Select the edited “custom_tags.ini” file and press Open. The file will get copied to the control. 10) Stop and start the appropriate wgui application Woodward...

  • Page 132: Appendixl Datalogs

    The control will store three log files per datalog type and will then overwrite previous datalog files when a new file is generated. The files are indexed with a value from 1 to 3 which increments each time a new file is generated. Woodward...

  • Page 133: Figure K-1. The Datalog Service Menu Page

    The Graph Properties page will open with the list of available signals in the left window. Signals to be plotted, referred to as pens, can be moved from the available signals list to the right window. Once in the right window, the pen color and order can be customized: Woodward...

  • Page 134: Figure K-2. Datalog Graph Properties

    In the bottom right-hand corner of the window, the ‘Time Difference’ is given in seconds and is the amount of time difference between the cursors. Please see the help menu within Control Assistant for detailed information on all menu options. Woodward...

  • Page 135: Figure K-3. Datalog Plot

    ‘Available Control’ list and add it to the ‘Controls to gather files from’ list. Within the ‘Datalog retrieval options’, set the folder on your PC where files will be stored. Press ‘OK’ to exit the configuration menu. Woodward...

  • Page 136: Figure K-4. Automated File Collection Configuration

    Automated File Collection > Start Automated File Collection Task. Once started, AppManager will display ‘Monitoring Network for New Files’ in the bottom window indicating that new files on the control are automatically saved to your PC. Woodward...

  • Page 137: Figure K-5. Automated File Collection Active

    Increment the revision number at the top for reference (this can be seen in GAP / WinPanel to verify file being used). Then use AppManager to place the file back on the control in the control applications folder. The datalogging must be stopped and then restarted to use the updated file. Woodward...
  • Page 138 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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