Woodward MicroNet TMR 5009C Product Manual
  1. Manuals
  2. Brands
  3. Woodward Manuals
  4. Control Systems
  5. MicroNet TMR 5009C
  6. Product manual
Woodward MicroNet TMR 5009C Product Manual

Woodward MicroNet TMR 5009C Product Manual

Digital control system
Hide thumbs Also See for MicroNet TMR 5009C:
Table of Contents

Advertisement

Quick Links

Download this manual
Product Manual 26320V1
(Revision B)
Original Instructions
MicroNet™ TMR 5009C
Digital Control System
Volume 1
Operations Manual
Manual 26320 consists of 3 volumes (26320V1, 26320V2, 26320V3).
Operations Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MicroNet TMR 5009C and is the answer not in the manual?

Questions and answers

Related Manuals for Woodward MicroNet TMR 5009C

Summary of Contents for Woodward MicroNet TMR 5009C

  • Page 1 Product Manual 26320V1 (Revision B) Original Instructions MicroNet™ TMR 5009C Digital Control System Volume 1 Operations Manual Manual 26320 consists of 3 volumes (26320V1, 26320V2, 26320V3). Operations Manual...

  • Page 2: General Precautions

    Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. 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

    6. S ............... 109  HAPTER ERVICE PTIONS   Product Service Options ..................109   Woodward Factory Servicing Options ..............110   Returning Equipment for Repair ................. 110   Replacement Parts ..................... 111   Engineering Services ..................111   How to Contact Woodward ................. 112  ...
  • Page 4 Remote Speed Set Point ..............37 Figure 4-1. Typical Dual Loop Valve with Cylinder’s LVDT and Pilot’s LVDT as   Represented in Woodward’s HMI ............ 40 Figure 4-2. Dual Control Loop Valve With Cylinder’s LVDT and Pilot’s LVDT and  ...
  • Page 5 Figure 5-7. Closed Loop Proportional, Integral and Derivative Action ....98   Figure 5-8. Typical Response to Load Change ..........100   Table 2-1. Redundancy Manager Truth Table ............8   Table 6-1. Actuator combo Driver Limits .............. 86 Woodward...

  • Page 6: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 7: 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 8 5009C Operations Manual 26320V1 Woodward...

  • Page 9: Chapter 1. General Information

    6. Perform a full system checkout; clear all system trips and alarms; adjust linkages and stroke actuators. When ready to start the turbine, follow the operation instructions of Chapter 5 in this volume. During initial start-up, the dynamics of each PID controller will need to be adjusted (Chapter 5). Woodward...
  • Page 10 5009C Operations Manual 26320V1 This volume provides control system description, and operation instructions for the Woodward MicroNet TMR 5009C Control System. It includes:  General description of the control system  Detailed functionality descriptions including I/O handling  Control system operation ...

  • Page 11: Chapter 2. Description

    Optionally the control can be configured to accept up to three speed sensor inputs, and three analog input signals (from separate transducers) for any single critical control parameter. Woodward...

  • Page 12: Figure 2-1. System Module Diagram

    2 Kernel Power Supply modules (3 typical)  2 CPU modules (3 typical)  2 Discrete I/O modules (3 typical)  1 Analog I/O module (3 typical)  1 Actuator module (2 typical)  1 Serial I/O module (2 typical) Woodward...

  • Page 13: Figure 2-2. Double Exchange And Vote Structure

    A speed input signal is determined to be faulty and is taken out of the input voting logic when it is below its “Speed Failure Level” setting. This failure level setting is common to all inputs and can be adjusted via the PCI program’s Service mode. Refer to Volume 3 for all PCI program procedures. Woodward...

  • Page 14: Analog Inputs

    (remote set point inputs). Each analog input can withstand up to two failures with no loss of control functionality. If any two of an analog input’s three “legs” are failed, the control uses the third healthy leg’s sensed input signal from which to control with. Woodward...

  • Page 15: Figure 2-3. Fault Tolerant Analog Input

    INPUT 1 TRANSDUCER #1 VOTING INPUT 2 INPUT CONTROL TRANSDUCER #2 LOGIC VOTING VOTING 855−662 02−12−31 INPUT 3 TRANSDUCER #3 VOTING Figure 2-3. Fault Tolerant Analog Input Woodward...

  • Page 16: Discrete Inputs

    If an input is determined to be faulty, the input is removed from the control’s voting logic and an input channel alarm is issued. Once the input fault is corrected the alarm condition can be reset by issuing a control “Reset” command. Woodward...
  • Page 17 The time between when a continuity check is performed and when the control redistributes current through the all drivers can be as long as 50 milliseconds. Woodward...

  • Page 18: Figure 2-5. Fault Tolerant Analog Output

    (leg) will drive the entire output. Figures 2-6 and 2-7 show a Fault Tolerant Actuator Output’s architecture. The Analog Termination Module (ATM) combines each actuator output signal from all three kernels into one signal at the ATM’s terminal blocks. Woodward...
  • Page 19 The time between when a continuity check is performed and when the control redistributes current through the all drivers can be as long as 50 milliseconds. Woodward...

  • Page 20: Figure 2-6. Fault Tolerant Single Coil Actuator Output

    5009C Operations Manual 26320V1 Figure 2-6. Fault Tolerant Single Coil Actuator Output Woodward...

  • Page 21: Figure 2-7. Fault Tolerant Dual Coil Actuator Output

    This does not mean that all actuators must be the same; they may be applied and setup differently as needed. Woodward...
  • Page 22 STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS DURING THIS PROCESS. The 5009C can be configured to utilize Woodward 2 Channel Actuator Modules and FTMs to drive a current source to the actuators. Each Valve is assigned two actuator drivers, whether wired in parallel to one actuator coil or separately to each coil in a dual coil actuator.

  • Page 23: Relay Outputs

    Latent fault detection is used to monitor the actual contact positions of each of the six relays, and to momentarily change states of each relay one at a time. This verifies each relay’s “normally open” or “normally closed” contacts. Woodward...

  • Page 24: Figure 2-8. Fault Tolerant Discrete Output

    CPU-B (RS-232) can also be configured to revert from its normal communications function to PCI (DDE) communications in the event that the kernel-C CPU fails. Once the Kernel-C CPU is restored and reset, the CPU-B port will revert back to its original functionality (Modbus or printer). Woodward...

  • Page 25: Figure 2-9. Fault Tolerant Dde Communication Ports

    When an SIO is installed, it will replace the CPU port for Modbus communication. SIO-A port 3 (RS-232/422/485) will replace CPU-A port, and SIO-B port 4 (RS-232/422/485) will replace CPU-B (if configured for Modbus). SIO-A port 4 (RS-232/422/485) and SIO-B port 3 (RS-232/422/485) can be configure as redundant Modbus lines. Woodward...

  • Page 26: Figure 2-10. Fault Tolerant Modbus Communication Ports

    With two SIO modules in one 5009C Control, up to three ports are available for Major Alarm/Trip printer communications. All communication output indications are also double exchanged between all three CPUs and voted on to vote out any erroneous output indications before the indication is output to the communications port. Woodward...

  • Page 27: Figure 2-11. Fault Tolerant Modbus Communication Ports

    Local mode settings to allow a customer to configure the interface lockout functionality desired. Optionally the control can be configured such that all interfaces are enabled at all times. Refer to Figure 2-12 for a graphical view of the control’s interface logic. Woodward...

  • Page 28: Figure 2-12. Interface/Communications Logic

    This control only accepts 4–20 mA signals. These 4–20 mA inputs, however, can be configured to interface with loop-powered or self-powered transducers, through ATM input wiring. Refer to Volume #3 for a complete list of all possible analog input functions. Woodward...
  • Page 29 LP2 valve (split, Extraction & Admission with separated valves) If an actuator combo output is not used to control a valve, then it can be configured as a simple 4–20 mA Analog readout, with the same option as for normal analog readouts. Woodward...

  • Page 30: Figure 2-13. Proportional Controller Diagram

    5 - PI Lead (integrating) Following are further descriptions of each type. Proportional Actuator (Proportional or PROP): Figure 2-13. Proportional Controller Diagram CTRL_TYPE = PROP = N/A = integral time constant T_LEAD = N/A LAG_RATIO = lag time constant Woodward...

  • Page 31: Figure 2-14. P Controller Diagram

    Tuning can be accomplished by increasing the gain until the actuator just starts to oscillate, then reducing the gain by a factor of 2. Integrating Actuator (PI): Figure 2-15. PI Controller Diagram CTRL_TYPE = PI = proportional gain = integral gain T_LEAD = N/A LAG_RATIO = N/A Woodward...

  • Page 32: Figure 2-16. Pi Lag Controller Diagram

    Integrating Actuator (PI Lead or PI_LEADLAG): Figure 2-17. PI Lead Lag Controller Diagram CTRL_TYPE = PI_LEADLAG = proportional gain = integral gain T_LEAD = lead time constant LAG_RATIO = lead/lag ratio Woodward...

  • Page 33: Figure 2-18. Three-Wire Transducer

    For devices with two pairs of return wires, the device manufacturer's drawing should be consulted to determine if it is a difference type or difference/sum type. Wiring methods for different transducer examples are shown below: Figure 2-18. Three-Wire Transducer Woodward...

  • Page 34: Figure 2-19. Four-Wire Transducer

    1A and 1B should be tied to the output center tap as shown. This device could be a simple difference or difference/sum type. Consult manufacturer to determine if this is an “A–B” or “(A–B)/(A+B)” type transducer. Figure 2-21. Six-Wire Transducer Woodward...

  • Page 35: Pilot Valve Control (Cascade Position Loop)

    K pilot * (Pilot null position- Pilot position) will be added to the valve demand. K pilot is the gain of this loop. Pilot null position is the pilot position when valve is stable. Range and null position are easy to set during Valve calibration. Woodward...

  • Page 36: Degraded Mode

    In cases where a device which is being interfaced to is located a distance of greater than 50 feet from the control, it is recommended that an RS-232-to- RS-422 converter, RS-232-to-RS-485 converter, or a Woodward SIO Module be used. Woodward...

  • Page 37: Pc Interface Program

    ServLink program to access and record control data. The DDE interface program allows non-Woodward software applications access to control data, for monitoring, trending, and report creating purposes. Refer to Volume 3 for details on connecting to the control via the ServLink program.

  • Page 38: Figure 2-22. Main Screen

    5009C Operations Manual 26320V1 Figure 2-22. Main Screen Woodward...

  • Page 39: Chapter 3. Control Functionality Overview

    50%. The control will continue to open both valves to 100%, with a position difference of 50%. GOVERNOR VALVE T&T VALVE INLET STEAM T&T VALVE INLET STEAM GOVERNOR VALVE 855−664 EXHAUST 98−03−12 JMM STEAM Figure 3-1. Typical Extraction and/or Admission Steam Turbine Woodward...

  • Page 40: Figure 3-2. Split Range Or Admission Type Of Turbine Configuration

    When system conditions cause a turbine to reach an operating limit (Min LP), only one process parameter can be controlled. The control’s limiter logic allows the process parameter which has priority on that limit to be controlled by limiting the second parameter. Woodward...

  • Page 41: Figure 3-3. Extraction And/Or Admission Steam Turbine

    (or Inlet/Exhaust pressure via decoupling) . Because a single admission turbine has only two control valves, only two parameters at a time can be controlled. By controlling valve interaction, the ratio logic minimizes the effects of one controlled process on the other controlled process. Woodward...
  • Page 42 PID relationships. Refer to the Ratio/Limiter section of this Volume for Ratio/Limiter configuration options. The 5009C is also capable to be configured for Extraction & Admission turbines having two separated LP valves. One used for extraction, one used for admission. Woodward...

  • Page 43: Block Diagrams

    PID relationship purposes only. For more information on the functionality of the Ratio/Limiter block, refer to the Ratio/Limiter Section of this manual. Figure 3-4. Overview of 5009C Control System Functionality Notes Woodward...

  • Page 44: Figure 3-5. Single Or Split-Range Turbine Configurations (Speed Pid With Remote Set Point)

    TO RPM CONVERSION SPEED CASCADE INPUT TURBINE SPEED RATIO/ LIMITER P’ DROOP SETPOINT EXT/ADM INPUT LP ACTUATOR ENABLE E/A DEMAND EXT/ADM OR EXT/ADM SETPOINT CONFIGURED LP VALVE LIMITER 855−769 05−9−12 Figure 3-7. Extraction and/or Admission Turbine Configurations (coupled mode) Woodward...

  • Page 45: Figure 3-8. Example Of A Single Stage Turbine Using Dual Loop Actuator And Remote Speed Set Point

    Manual 26320V1 5009C Operations Figure 3-8. Example of a Single Stage Turbine using Dual Loop Actuator and Remote Speed Set Point Woodward...

  • Page 46: Chapter 4. Control Functionality

    For Extraction valves, care should be taken that an actuator channel has been allocated for LP valve using the PCI software. Failure to do so, will maintain the LP closed, resulting to a possible damage of the engine while starting. Woodward...
  • Page 47 The cylinder movement will depend on the pilot NULL position. When the pilot deviates from its null position, the cylinder will continuously open or close (integrating). Therefore, it is necessary to control not only the cylinder position, but also the pilot position. Woodward...

  • Page 48: Figure 4-1. Typical Dual Loop Valve With Cylinder's Lvdt And Pilot's Lvdt As Represented In Woodward's Hmi

    Due to the valve’s design, it might be impossible to install redundant Pilot LVDT. To compensate this lack of redundancy, Woodward has developed a unique algorithm, capable to maintain the valve in stable operation, even if the Pilot valve feedback position as failed.

  • Page 49: Figure 4-2. Dual Control Loop Valve With Cylinder's Lvdt And Pilot's Lvdt And Degraded Mode

    Manual 26320V1 5009C Operations Figure 4-2. Dual Control Loop Valve With Cylinder’s LVDT and Pilot’s LVDT and Degraded Mode Woodward...

  • Page 50: Turbine Start Modes

    100%. When turbine speed increases to the minimum controlling speed (idle or min control speed), the control’s Speed PID will take control of turbine speed through positioning the turbine’s inlet HP valve. The following start-up procedure is employed when the Manual start mode is configured: Woodward...

  • Page 51: Figure 4-3. Manual Start Mode Example

    100% Operator Must Throttle Open Trip & Throttle Valve TIME START SPEED COMMAND CONTROL Figure 4-3. Manual Start Mode Example Woodward...

  • Page 52: Figure 4-4. Semiautomatic Start Mode Example

    PCI, external contacts, or Modbus commands. The HP valve limiter rate, and the rate-to-min settings are tunable via the PCI program’s Service mode. 100% Operator Must Manually Raise Valve Limiter TIME START SPEED COMMAND CONTROL Figure 4-4. Semiautomatic Start Mode Example Woodward...

  • Page 53: Figure 4-5. Automatic Start Mode Example

    Speed will ramp up to and remain at the minimum controlling speed until action is taken by the operator or the auto start sequence, if programmed, will continue its sequence. 100% TIME START SPEED COMMAND CONTROL Figure 4-5. Automatic Start Mode Example Woodward...
  • Page 54 If the difference is greater than the max speed deviation authorized, during more than the Alarm delay, an alarm will be generated.  If SD option is selected, ff the difference is greater than the max speed deviation authorized, during more than the SD delay, a shutdown will be generated. Woodward...

  • Page 55: Zero Speed Signal Override

    When this option is selected from PCI Software, once the engine has reached min governor speed, this protection is activated. If the speed PV becomes lower than the underspeed level, during more than the alarm delay, an alarm is generated, and, if configured a shutdown can be generated. Woodward...

  • Page 56: Valve Limiters

    PCI program’s Service Mode. When automatic start is selected, any R/L command on the HP valve limiter will stop the automatic ramp up. To re-initiate an automatic ramp-up, START command must be given (even if engine is already running) Woodward...

  • Page 57: Turbine Start Routine

    (at the idle settings) to use during the start routine, based on the hours-since-trip timer. This timer starts when a shutdown has been executed and turbine speed has decreased below the low idle speed setting. Woodward...

  • Page 58: Figure 4-6. Automatic Start Sequence

    RATE TO HI IDLE (HOT) RPM/SEC HI IDLE DELAY TIME (COLD) MINIMUM HI IDLE DELAY TIME (HOT) MINIMUM RATE TO RATED (COLD) RPM/SEC RATE TO RATED (HOT) RPM/SEC RATED SETPT 3400 LOADING GRADIENT (COLD) 10 RPM/S LOADING GRADIENT (HOT) 20 RPM/S Woodward...
  • Page 59 5 minutes. However, if the speed reference is above the Idle level (manually raised), the autostart sequence will ramp to the next level, regardless to the hold timer. Woodward...

  • Page 60: Critical Speed Avoidance

    (based on the critical speed rate & range). If the “stuck in critical” alarm occurs on a regular basis, it may be indicating that the critical speed rate is set too fast for the turbine to respond to. Woodward...

  • Page 61: Speed Control Overview

    The 5009C Control’s Speed PID compares this speed signal to a setpoint to generate a speed/load demand signal to the Ratio/Limiter in an extraction and/or admission turbine, and to the low signal select bus for a non- extraction turbine. Figure 4-7. Speed Control Functional Diagram Woodward...

  • Page 62: Speed Pid Operational Modes

    (LAG) should be equal or lower than the surge time loop, and will not correct the speed in normal operation. In case of compressor surge, huge speed upset may occur, and recovery might be very difficult. Woodward...
  • Page 63 1 (max value possible is 2)  To avoid interaction with the speed controller, the HP compensation signal should be Delayed (Lagged). It is also possible to use the cascade input as a pressure compensation signal (configurable in PCI) Woodward...
  • Page 64 Speed Set Point setting unless an overspeed test is performed. Once the Speed Set Point is taken above the minimum governor Speed Set Point, it cannot be varied below this setting again unless a controlled stop is selected. Woodward...

  • Page 65: Figure 4-8. Speed Relationships

    The RSS range is determined by the programmed analog input’s 4 mA and 20 mA settings. The RSS range is tunable in the Service Mode, but cannot control outside of the minimum and maximum governor Speed Set Points. Woodward...

  • Page 66: Valve Redundancy Controller

    Manual transfer between converters can be initiated through discrete input, Modbus, or pc interface commands. Automatic transfer between converters is provided by the 5009C based on driver failure(s), converter status, converter output pressures, and servo input pressure feedback signals. Woodward...

  • Page 67: Figure 4-9. Typical Redundant I/H System With A Transfer Valve

    Manual 26320V1 5009C Operations Figure 4-9. Typical Redundant I/H System with a Transfer Valve Figure 4-10. Typical Redundant I/P System with a Pressure Selecting Relay Valve Woodward...
  • Page 68 Care must be taken to ensure the converters will not fail to a high pressure output condition. The Woodward CPC (I/H) for example, will not fail high, on an internal failure the hydraulic pressure is ported to drain. The converters must be set up with an offset such that one is the primary controller and the other is the backup, without an offset the controllers would tend to fight each other.
  • Page 69 Max Time to Detect Standby timer expires (Service Mode adjustment defaulted to 5 seconds) OR  the Standby Control Duration timer expires (this is the time delay required, after standby control is confirmed, to determine the health of the standby unit). Woodward...
  • Page 70 If both I/H are determined to be failed, an alarm is issued - the 5009 can be programmed to trip, see Programming options. If both I/H have faults and one I/H becomes healthy, the output will automatically transfer to the healthy I/H. Woodward...
  • Page 71 A&B output, and the other to C output ACT1-2: When both actuator output are controlling the same valve, via two different actuators ACT-FDBK 1-2: When actuator cards Channel 1 and Channel 2 outputs are controlling the same valve, via two different actuators Woodward...

  • Page 72: Extraction, Admission, Or Extr/Adm Turbine Control

    100% position upon issuing a reset command to the control. This allows the turbine to warm-up and expand evenly, before starting the turbine. Upon a shutdown condition, the LP valve limiter is taken to 0%. Figure 4-11. Ext/Adm Control Diagram Woodward...
  • Page 73 LP valve’s current position and then raise the LP limiter to its maximum (open) position at the LP valve limiter rate. At some point, depending on system conditions, the Extraction PID will lose control of its process. Woodward...
  • Page 74 Adm PID is not enabled, this flow setpoint is the “P” term input into the control’s Ratio/Limiter. This flow demand setpoint is defaulted to 100% for Admission turbines, and to a calculated zero ext/adm flow point for Extr/Adm turbines. All default settings can be changed via the PCI program’s Service mode. Woodward...
  • Page 75 The control senses an input failure and issues an alarm if the 4–20 mA Ext/Adm input signal goes < 2 mA or > 22 mA. Refer to Chapter 2 of this Volume for details on input fault tolerant logic. Woodward...

  • Page 76: Set Point

    The extraction set point , when extraction is disable or in manual mode can be set for tracking or not tracking. If tracking is selected, the setpoint will track the process value as long as the control is disabled or in manual mode. Woodward...
  • Page 77 Due to a turbine’s design, the positioning of either valve (HP or LP) has an effect on both parameters being controlled. This interaction between valves (controlled parameters) can cause undesirable fluctuations in a process not requiring a change. Woodward...
  • Page 78 The movement of both valves is automatically calculated by the 5009C Control’s ratioing logic based on the programmed turbine performance parameters to minimize valve/process interaction. Refer to Figure 4-12 for details on the Coupled HP&LP mode logic. Woodward...
  • Page 79 For a change in either process the valves are repositioned to create a net effect of no pressure or flow change on the other process. Refer to Figure 4-14 for details on the Decoupled Exhaust mode logic. Woodward...
  • Page 80 Refer to Figure 4-14 for details on the Decoupled HP&LP mode logic. Block Diagram Description—The block diagrams displayed below provide a detailed view of each Ratio/Limiter configuration, and the relationship between the ratio/limiter’s input and output signals. Woodward...
  • Page 81 LPmax priority is selected, Extraction/decoupling pressure will have priority over the speed controller. When limit is reached, the Speed reference cannot be raised (even via cascade) as long as this limit is reached. If not selected, the extraction/admission will be Limited when this limit is reached. Woodward...

  • Page 82: Figure 4-12. Coupled Hp & Lp Mode

    5009C Operations Manual 26320V1 Figure 4-12. Coupled HP & LP Mode Woodward...

  • Page 83: Figure 4-13. Decoupled Inlet Or Exhaust Mode

    Manual 26320V1 5009C Operations Figure 4-13. Decoupled Inlet or Exhaust Mode Woodward...

  • Page 84: Cascade Control

    When enabled, the Cascade PID can move the Speed Set Point at a variable rate up to the maximum Speed Set Point rate, which is set in the Program Mode. Turbine speed must be greater than the minimum governor setpoint before the Cascade PID can begin controlling. Woodward...

  • Page 85: Figure 4-15. Cascade Functional Diagram

    Cascade Dynamics The Cascade PID control uses its own set of dynamic settings. These values are programmable and may be tuned at any time from PC Interface or Modbus. Refer to the PID Dynamic Adjustments section in Chapter 6. Woodward...

  • Page 86: Cascade Droop

    HP control valve position must be decreased. Remote Cascade Set Point The cascade setpoint can be positioned through an analog signal. This allows the cascade setpoint to be positioned remotely by a process control or distributed plant control system. Woodward...

  • Page 87: Seal Gas Pid Control

    In PCI software, it is possible to inhibit the manual mode selection. In this case, Seal Gas PID will be in manual mode only when its process value is lost. Should a Process value be lost, it is also possible to configure the 5009C to ramp the PID output up or down automatically. Woodward...

  • Page 88: Emergency Shutdown

    When an Emergency Shutdown condition occurs, both valve output signals are stepped to zero milliamps, and the Shutdown Relay(s) de-energize(s). For actuator outputs from actuators, the Driver SD can be disabled, in order to send negative current during SD. Woodward...

  • Page 89: Controlled Shutdown

    5a. If the Normal SD has been configured to not issue a SD, the engine is set to “ready to start” and wait for a start command. If not, 6. The 5009C Control executes a Shutdown (Shutdown Relay de-energizes, actuator drive currents = zero). 7. A ‘Shutdown - Controlled Stop’ message is indicated. Woodward...

  • Page 90: Local / Remote Function

    Port 3 ‘CPU’ Settings). If this function is not programmed all contact inputs and Modbus commands (when Modbus is programmed) are active at all times. If the Local/Remote function is programmed, Local and Remote modes can be selected through a programmed contact input, the PCI program, or Modbus. Woodward...
  • Page 91 #1, and/or Modbus port #2 when the Local mode is selected. All pertinent Local/Remote control parameters are available through the Modbus links. It is possible to configure the 5009C so that the contact input sends only a “LOCAL” or only a “REMOTE” command. This option enables Flip-Flop commands. Woodward...

  • Page 92: Relays

    Control relay to be driven directly from Modbus to control a system related function (synchronizing). Each of the nine relay can be configured for “lamp usage”. In this case, this relay will be energized, as soon as a lamp test is requested from contact or PCI only. Woodward...

  • Page 93: Chapter 5. 5009C Control System Operation

    LED is the only power supply LED on. 5. Momentarily toggle the A, B, & C-Rack’s CPU’s RESET switch up (press the switch’s top half), then back to its normal down position (press the switch’s bottom half). Woodward...

  • Page 94: Valve / Actuator Calibration & Test

    100 mA (for the 20–160 mA option) or 12 mA (for the 4–20 mA option). If necessary, the actuator to valve linkage may need to be adjusted to ensure proper 5009C to valve resolution. Woodward...
  • Page 95 8. PCI/Modbus : Select the “Go Max” button to Step the actuator driver output to its maximum output current level. For integrating valves, the cylinder LVDT 0% position as well as the pilot 0% (if used) will be memorized. Woodward...
  • Page 96 13. Repeat steps 4 through 11 for each valve to be calibrated. For Actuator card outputs, each card (A106 and C106) must be calibrated independently prior to run the engine. Woodward...

  • Page 97: Turbine Start

    For a detailed description of the screens and access to those parameters, refer to Volume 3 for the PCI and Volume 4 for the HMI. If configured, contact inputs will perform the same functions in the 5009C Control. Woodward...

  • Page 98: Auto Start Sequence

    Integral is a function of the magnitude and duration of the deviation. In this analogy the reset response would keep the car speed constant regardless of the terrain. Woodward...
  • Page 99 Stability is of course also affected by the stability of the process. In essence, the amount of output from the controller due to the Proportional setting is from the error. If there is no error, then there is no Proportional effect. Woodward...

  • Page 100: Figure 5-1. Proportional Gain Setting Effects

    Figure 5-1. Proportional Gain Setting Effects 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 101: Figure 5-2. Open Loop Proportional And Integral Response

    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. Woodward...

  • Page 102: Figure 5-3. 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 103: Figure 5-4. Integral Gain (Reset) Setting Responses

    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

    0.2 is in the dominance feature. If in doubt about the type of derivative to use, then set up for feedback dominant, 1 < DR < 100. Proportional + Derivative (Closed Loop) Figure 5-5. Closed Loop Proportional and Derivative Action Woodward...

  • Page 105: Figure 5-6. Derivative Setting Effects

    Derivative is added to the point of removing only one cycle from the 1/4 decay ratio then the gain is increased until the 1/4 decay ratio is restored. In all the above curves, you will note offset exists since offset can only be eliminated by the addition of Integral (or Reset). Woodward...

  • Page 106: Figure 5-7. Closed Loop Proportional, Integral And Derivative Action

    After Proportional is set to 1/4 decay ratio and Derivative is adjusted to remove one cycle as well as decreasing the 1/4 decay ratio, then the Proportional gain can be increased to restore the 1/4 decay ratio. Woodward...

  • Page 107: General Field Tuning Guidelines

    After each setpoint change, allow sufficient time to observe the effect of the last adjustment (see Figure 5-8). It is wise to wait until approximately 90% of the change has been completed. Woodward...

  • Page 108: Figure 5-8. Typical Response To Load Change

    The optimum gain for this step is when the system just starts to oscillate and maintains a self-sustaining oscillation that does not increase or decrease in magnitude. 4. Record the control gain (Kc) and oscillation period (T) in seconds. Woodward...

  • Page 109: Speed, Casc, Decoupling, Seal Gas Pid, And Ext/Adm Dynamics Adjustments

    Then adjust the integral gain as necessary to stabilize the output. If stability cannot be obtained with the integral gain adjustment, reduce the proportional gain setting. A well tuned system, when given a step change, should slightly overshoot the control point then come into control. Woodward...

  • Page 110: Tuning Derivative

    The change from one of these configurations to the other may have no effect during normal operation, however, it can cause great differences in response when the governor is coming into control. (at start-up, during a full load change, or during transfer of control from another channel). Woodward...

  • Page 111: Overspeed Test Function

    (External Test) setting for more than 60 seconds (as defaulted in Service mode) without any adjustment to the speed set point, an emergency shutdown will be issued.  The programmable “Overspeed Trip” indication relay only energizes when an Emergency shutdown is performed due to an Overspeed Trip condition. Woodward...
  • Page 112 There are two programmable relay options available to indicate overspeed status. One programmable relay option indicates an Overspeed Trip condition. The second relay option provides indication that a Overspeed Test is being performed. All pertinent overspeed test parameters are available through Modbus. Woodward...

  • Page 113: Operation Information

    Because the Cascade controller changes the speed setpoint and not the actual LSS bus, whenever the Cascade is disabled, a bumpless transfer back to speed control occurs. The raise and lower speed commands are then enabled. Woodward...
  • Page 114 The rate at which the cascade setpoint changes is independent of the P, I, & D terms of the actual cascade PID. Moving the setpoint at a slower rate will not slow down the rate at which the Cascade controller moves the speed setpoint. Woodward...

  • Page 115: Extraction/ Admission Control

    LOWER Extr/Adm commands. If setpoint tracking has been disabled, the valve limiters as described above are used to slowly bring the Extr/Adm input into the control range. Once the Extr/Adm controller is in control, the RAISE and LOWER Extr/Adm commands will then change the Extr/Adm setpoint. Woodward...
  • Page 116 (OpView, PCI program). Relay outputs can be configured in the PCI program for some individual alarm/trip indications (Refer to Volume 3) and also for any alarm/trip present indication. But for a description and time stamping as described in the following chapter, a Modbus port must be used. Woodward...

  • Page 117: Chapter 6. Service Options

    Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. You can locate your nearest Woodward distributor, AISF, RER, or RTR on our website at: www.woodward.com/directory...

  • Page 118: Woodward Factory Servicing Options

    Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in “like- new” condition and carry with it the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is applicable to mechanical products only.

  • Page 119: Packing A Control

    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 120: How To Contact Woodward

    5009C Operations Manual 26320V1 How to Contact Woodward For assistance, call one of the following Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service.
  • Page 121 Manual 26320V1 5009C Operations Woodward...
  • Page 122 Declarations...
  • Page 124 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.

Table of Contents